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

USER INFORMATION
6
1 User Information
The User Information chapter provides information about
using
the operating manual.
1.1 Purpose of the document
The present operating manual:
•describes
the operation and maintenance for the special
tool.
•provides important information for safe and efficient
handling of the special tool.
•is an integral part of the special tool and must alwa
ys be
kept accessible in the vicinity of the special tool.
•must be kept for future use.
•must be passed on to the purchaser if the special tool is
sold.
1.2 Location details in the operating manual
All direction statements in this operating manual are always
in the direction of the front side of the special tool. The
reversible thread adapter is always on the left here.
1.3 Illustrations used
Handling instructions and reactions
Activities to be performed by the operator are shown as
numbered instructions. Comply with the sequence of the
specified instructions. The reaction to the respective
instruction is marked by an arrow if necessary. Example:
1. Instruction 1
→Reaction of the special tool to instruction 1
2
.
Instruction 2
Lists
Lists without a mandatory sequence are shown as a list with
bullet points. Example:
•Point 1
•Point 2

7
Position numbers in figures
Numbers in round brackets refer to position numbers in
figures. The first number refers to the figure and the second
number to the position number in the figure.
Example (Fig. 3/6)
•Figure 3
•Position 6
1.4 Terms used
The term ... means ...
Third party ... all persons except the operator.
Hazard ... the source of a possible injury or harm to health.
Manufacturer ... the company WALTERSCHEID GMBH.
Control ... the part which is directly operated by the operator, e.g. by
pressing. A control can be a control lever, rocker switch,
button, rotary switch etc.

PRODUCT DESCRIPTION
8
2 Product Description
This chapter contains:
•comprehensive information about the design of the
WALTERSCHEID special tool SW42,
•the names of the individual assemblies and controls.
If possible, read this chapter directly at the special tool. This
will best familiarise you with the special tool.

9
2.1 Overview – assemblies
Illustration of the special tool SW42 and designation of the most important elements.
Fig. 1
(1) Hydraulic motor
(2) Gearbox
(3) Measuring hub, for holding various profile pins
(4) Base
(5) Carriage, for holding the torque support
(6) Two-hand control

PRODUCT DESCRIPTION
10
Fig. 2
(1) Hydraulic motor
(2) Gearbox
(3) Changeover valve for tester rotation direction (of the measuring hub)
(4) Measuring hub
(5) ON / OFF switch with green LED lamp lights when measuring hub is switched on
(6) DC input for charging the measuring hub battery
(7) LED lamp for battery charge status lights when battery is discharged
(8) Base
(9) Carriage
(10) Hydraulic hose lines with protective tube
(11) Hydraulic unit (optional)

11
2.2 Safety devices and protective equipment
This chapter shows the arrangement of the correctly
mounted safety devices and protection equipment in the
safety position.
WARNING Hazards for persons can arise from ejected objects if
the required safety devices and protection equipment
are not present during operation!
•Only put the special tool into operation when safety
devices and protective equipment are completely
installed.
•Replace defective safety devices and protective
equipment immediately with new ones.
(1) Two-hand control
Fig. 3
(2) Protective tube on the respective
hydraulic hose line to the hydraulic
unit
Fig. 4

PRODUCT DESCRIPTION
12
2.3 Intended use
The WALTERSCHEID special tool SW42 is exclusively
intended for testing the functionality of overload clutches
during repairs, reassembly or adjustment by qualified skilled
personnel. Overload clutches with a maximum torque of up
to 500 daNM (5000 Nm) can be tested.
Intended use also includes:
•compliance with all instructions in this operating manual,
•compliance with the specified work for maintenance a
nd
care of the special tool,
•the exclusive use of original parts.
Any uses other than those above are prohibited and are
deemed as non-intended use.
For damage arising from non-intended use:
•the owner bears the sole responsibility,
•the manufacturer accepts no liability of any kind.
2.4 Danger zone and danger points
The danger zone is the area between the mounted overload
clutch and the mounted torque support in which hazards for
the safety or health
of persons arise when the test process is
started.
No persons must reach into the danger zone during the start
of the test process.
The operator is only permitted to start the test process if no
persons are present in the danger zone.
There are hazards in the danger zone from danger points
which cannot be completely eliminated with respect to the
functional safety of the special tool. The hazards are always
present.
Danger points on the special tool are identified with warning
signs. The warning signs warn about the residual risks.
Action-related safety instructions in this operating manual
indicate the existing residual risks of the special tool.

13
2.5 Type plate and CE marking
The following illustration shows the layout of the type plate
an
d
CE
marking
.
The complete marking has official status and must not be
modified or rendered unrecognisable.
The type plate shows:
•Type
•Serial No.
•Manufacturer
•Connected loads
Fig.
5
2.6 Technical data
Tester
Weight: kg 160
Dimensions:
•
Length
mm
700
•
Width 600
•
Height 600
Gearbox oil: SAE 90 GL 4
Test speed: rpm Setpoint 2.5 (1.5 to 4 permissible)
Hydraulic unit (if included in the order)
Weight: kg 30
Dimensions:
•
Length
mm
600
•
Width 300
•
Height 270
Hydraulic oil: HLP 46
Maximum operating pressure: bar 150
Flow rate: l/min 6±2
Electric motor:
•
Voltage: Volt 220 – 240 V (50 – 60 Hz)
•
Power: W 1,500

PRODUCT DESCRIPTION
14
2.7 Conformity
The WALTERSCHEID special tool SW42 for checking the
functionality of overload clutches during repair, reassembly
or adjustment complies with the basic health and safety
requirements of the following Directive and standards:
•
Directive 2006/42/EC
•EN ISO 12100:2010
•EN ISO 4413:2010
•EN 574:1996+A1:2008
The manufacturer confirms that the Special Tool SW42
complies with the basic health and safety requirements:
•by the issue of the declaration of conformity,
•by the application of the CE marking to the special tool.
In the case of non-approved structural changes and
attachments or conversions:
•the declaration of conformity and the CE marking of the
special tool lose their validity,
•warranty claims and liability claims for personal injuries
and damage to property are excluded by the
manufacturer,
•the owner bears the responsibility.

SAFETY INSTRUCTIONS
15
3 Safety Instructions
This chapter contains important information for the owner
and the operator about the safe and faultless operation of
the special tool.
Comply with all safety instructions in this operating
manual.
Most accidents are caused by non-observance of the
simplest safety regulations.
You help to prevent the occurrence of accidents by
observing all the safety instructions in this operating manual.
3.1 Safety-conscious working
The special tool has been built in accordance with the state
of the art and the generally recognised rules of technology.
Nevertheless, hazards and adverse effects can arise during
use of the special tool:
•for the life and limb of the operator or third persons,
•for the special tool itself,
•to other property.
Observe the following for the safe operation of the special
tool:
•this operating manual, particularly:
othe basic safety instructions, the action-related
safety instructions and the action instructions,
othe information about intended use.
•the warnings on the special tool,
•the national, generally applicable regulations for
occupational health and safety, accident prevention and
environmental protection.
Only operate the special tool when it is in a technically
fault
le
ss
cond
ition.

SAFETY INSTRUCTIONS
16
3.2 Organisational measures
The operating manual:
•always keep at the usage location of the special tool,
•must be freely accessible at any time to the operator
and maintenance personnel.
3.2.1 Obligations of the owner
The owner is obligated:
•to comply with the national, generally applicable
regulations for occupational health and safety, accident
prevention and environmental protection,
•to only allow persons to work with/on the special tool
who:
oare familiar with the basic requirements for
occupational health and safety and accident
prevention,
ohave been instructed about working with/on the
special tool,
ohave read and understood this operating manual.
•to keep all warning signs on the special tool in legible
condition,
•to replace damaged warning signs,
•to provide the required personal protective equipment,
such as:
osafety goggles,
owork gloves according to DIN EN 388,
osafety footwear,
oprotective clothing,
o
barrier cream, etc.

17
3.2.2 Obligations of the operator
All persons who are assigned to working with/on the special
tool are obliged, before starting work:
•to comply with the national, generally applicable
regulations for occupational health and safety, accident
prevention and environmental protection,
•to read and observe the chapter "Basic safety
instructions" starting on page 22 of this operating
manual,
•to read the chapter "Warnings and instructions" starting
on page 27 of this operating manual and to observe the
warnings during operation of the special tool,
•to familiarise themselves with the special tool,
•to read the chapters of this operating manual which are
important for carrying out the work assigned to them.
If the operator discovers th
at the equipment is not technically
safe, the operator must rectify this defect immediately. If this
is not part of the operator's work assignment or he does not
have the corresponding technical knowledge, the operator
must notify the defect to his supervisor or the owner.

SAFETY INSTRUCTIONS
18
3.2.3 Qualification of the persons
Only trained and instructed persons are permitted to work
with / on the special tool. The owner must clearly specify the
responsibilities for operation, maintenance and repairs.
A person undergoing training is only permitted to work with /
on the special tool under the supervision of an experienced
person.
The owner is only permitted to carry out the work described
in this operating manual.
Only specialist workshops are permitted to carry out work on
the special tool which requires particular technical
knowledge. Specialist workshops have qualified personnel
and suitable auxiliary equipment (tools) for the proper and
safe performance of this work.
This applies to all work:
•which is not mentioned in this operating manual,
•which is identified with the addition of "workshop work"
in this operating manual.

19
Persons
Activity
Person
specially
trained for the
activity
1)
Instructed
person
2)
Persons with
specialist training
(specialist workshop)
3)
Loading / Transport X X X
Start-up -- X X
Installation, setting up -- X X
Operation -- X X
Cleaning, maintenance and
repairs
-- X X
Troubleshooting and fault
clearance
-- X X
Disposal X -- --
Legend: X..allowed --..not allowed
1)
A person who can take over a specific task and is
permitted to perform this for a correspondingly qualified
company.
2)
An instructed person is a person who has been
instructed and if required trained about the tasks
assigned to him and possible dangers in the case of
improper behaviour and who has been instructed about
the necessary safety devices, protective equipment and
safety precautions.
3)
Persons with specialist training are skilled persons
(specialists). On the basis of their professional training
and knowledge of the relevant conditions, they can
assess the work assigned to them and recognise
possible dangers.
Note: An equivalent qualification to technical training
can also be acquired by several years of experience in
the work area concerned.

SAFETY INSTRUCTIONS
20
3.3 Product Safety
3.3.1 Safe operation of the special tool
Only one person is permitted to operate the machine if there
are no other persons in the danger zone of the special tool.
See also the chapter "Danger zone and danger points",
page 12.
3.3.2 Safety devices and protective equipment
•
Only operate the special tool if all safety devices and
protective equipment have been installed properly and
are completely functional.
Defective or removed safety devices and protective
equipment can result in dangerous situations.
•Check all safety devices and protective equipment for
externally recognisable damage and functionality before
you put the special tool into operation.
3.3.3 Structural changes
•
Structural changes, attachments or conversions to the
special tool must only be made with the manufacturer's
written permission.
•In the case of non-approved structural changes,
attachments or conversions, the declaration of
conformity and the CE marking of the special tool lose
their validity.
•Only use original parts or conversion and accessory
parts approved by the manufacturer so that:
o
the declaration of conformity and the CE marking
of the special tool retain their validity,
othe faultless function of the special tool is
guaranteed.
•The manufacturer shall not be liable for damage caused
by:
ounauthorised modifications of the special tool,
onon-approved conversion and accessory parts,
owelding and drilling work on load-
bearing parts of
the
special tool.