TorcUP TX Series User manual

1
OPERATION AND MAINTENANCE
MODELS TX-1, TX-2, TX-4, TX-8, TX-16, TX-32, TX-45
MANUAL
TX Series
Low Prole Hydraulic Torque Wrenches
TX Series
Phone: [phone]
Fax: [phone]
Toll Free: 1-888-TORCUP-1
Email: [email protected]
Website: www.torcup.com
1025 Conroy Place, Easton PA 18040 U.S.A.

1
Operational and Maintenance Manual for TorcUP
TX-1, TX-2, TX-4, TX-8, TX-16, TX-32 and TX-45
Low Prole Hydraulic Torque Wrenches
Version 2: 2016 September
Series TX-1, TX-2, TX-4, TX-8, TX-16, TX-32 and TX-45 Low Prole Hydraulic Torque Wrenches are
designed for installing and removing threaded fasteners having minimal wrench clearance and requiring
precise high torque during bolt makeup and maximum torque for bolt breakout.
TorcUP Inc. is not responsible for customer modication of tools for applications on
which TorcUP Inc. was not consulted.
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ THIS MANUAL BEFORE OPERATING TOOL.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS
MANUAL INTO THE HANDS OF THE OPERATOR.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
USING THE TOOL
• Always operate, inspect and maintain this tool in accordance with American National Standards
Safety Code for Hydraulic Rams and Jacks (ANSI B30.1).
• This tool will function using an air or electric powered hydraulic pump. Adhere to the pump safety
requirements and follow instructions when connecting the pump to the tool.
• Use only equipment rated for the same pressure and torque.
• Use only a hydraulic pump capable of generating 10,000 psi (681 bar) maximum pressure with this
tool.
• Use only twin line hydraulic hose rated for 10,000 psi (681 bar) pressure with this tool.
• Do not interchange the male and female swivel inlets on the tool or the connections on one end of
the hose. Reversing the inlets will reverse the power stroke cycle and may damage the tool.
• Do not use damaged, frayed or deteriorated hoses and ttings. Make certain there are no cracks,
splits or leaks in the hoses.
• Use the quick connect system to attach the hoses to the tool and pump.
• When connecting hoses that have not been preloaded with hydraulic oil, make certain the pump
reservoir is not drained of oil during start-up.
• Do not remove any labels. Replace any damaged label.
• Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing
serious injury. If oil is injected under the skin, see a doctor immediately.
• Never pressurize uncoupled couplers. Only use hydraulic equipment in a coupled system.
• Always wear eye protection when operating or performing maintenance on this tool.
• Always wear head and hand protection and protective clothing when operating this tool.
NOTICE
WARNING
For Technical Support & Information Contact:
TorcUP Inc.
1025 Conroy Place, Easton, PA 18040 USA
Phone: [phone] Fax:[phone]
email: [email protected]
The use of other than genuine TorcUPreplacement parts may result in safety
hazards, decreased tool performance, increased maintenance, and may invalidate
all warranties. Repairs should be made only by authorized personnel. Consult
your nearest TorcUPAuthorized Service Center.
Refer All Communications to the Nearest TorcUP Ofce or Distributor.

2
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY
Do NOT Exceed Maximum Pressure. See Torque Chart with Tool. Damage May Occur.
Always wear eye
protection
when operating or
performing
maintenance
on this tool.
Always wear ear
protection
when operating
this tool.
Do not carry
the tool
by the hose.
Keep body stance
balanced and rm.
Do not overreach
when operating this
tool.
USING THE TOOL
• Keep hands, loose clothing and long hair away from the reaction arm and working area during operation.
• This tool will exert a strong reaction force. Use proper mechanical support and correct reaction arm
positioning to control these forces. Do not position the reaction arm so that it tilts the tool off the axis of the
bolt and never use the swivel inlets as a reaction stop.
• Avoid sharp bends and kinks that will cause severe back-up pressure in hoses and lead to premature hose
failure.
• Use accessories recommended by TorcUP.
• Use only impact sockets and accessories. Do not use hand (chrome) sockets or accessories.
• Use only sockets and accessories that correctly t the bolt or nut and function without tilting the tool off the
axis of the bolt.
• This tool is not insulated against electric shock.
• This equipment must not be operated or serviced unless the operator read the operating instructions and
fully understands the purpose, consequences and procedure of each step.
• When operating a larger tool (TX-16, TX-32, or TX-45) above waist height, employ a secondary means of
support for safety purposes. A tool sling or chains may be used. Consult your safety department for further
suggestions.
Depending on the working environment your local health and safety regulations may require
you wear protective gear (i.e. safety shoes, hard hat, gloves, coveralls, etc.). In case
external forces are exerted on the equipment, non-compliance with these regulations may
result in injury. EAR PROTECTION MUST BE WORN WHEN OPERATING THIS TOOL.
The Torque Reaction Arm must be
positioned against a positive stop.
Do not use the arm as a dead
handle. Take all precautions to
make certain the operator’s hand
cannot be pinched between
the arm and a solid object.
Do not use damaged,
frayed or deteriorated
hydraulic hoses
and ttings.
WARNING

3
PLACING THE TOOL IN SERVICE
SETTING THE TORQUE
After determining the desired torque, use the torque conversion charts on pages 7 to 20 to determine
the pressure that is necessary to achieve that torque.
1. Connect the tool to the power supply and turn the pump on.
2. Depress the remote control button causing the pressure to be shown on the gauge.
3. Adjust the pressure by loosening the wing nut that locks the pressure adjustment thumbscrew.
Rotate the thumbscrew clockwise to increase the pressure and counterclockwise to decrease the
pressure. When decreasing pressure, always lower the pressure below the desired point and then
bring the gauge back up to the desired pressure.
4. When the desired pressure is reached, retighten the wing nut and cycle the tool again to conrm
that the desired pressure setting has been obtained.
OPERATING THE WRENCH
The position of the tool relative to the nut determines whether the action will tighten or loosen the
nut. (Refer to Dwg. 2 for application
examples). The power stroke of the
piston assembly will always turn the
ratchet hex toward the shroud.
1. Place the ratchet hex on the nut. Make
certain it is the correct size for the nut
and that it fully engages the nut.
2. Position the reaction surface against
an adjacent nut, ange or solid system
component. Make certain that there is
clearance for the hoses, swivels, and
inlets. DO NOT allow the tool to react
against the hoses, swivels, or inlets.
Wrench Positions Dwg. 2
CONNECTING THE TOOL
1. Attach the twin line hose to the
swivel inlets of the square drive
torque wrench using the spring–
loaded quick connect ends.
2. Connect the opposite ends of the
hose to the pump in the same
manner.
3. Push the link retaining pin out of
the low prole drive cylinder.
4. Mate the selected ratchet link to
the cylinder by inserting the end
of the cylinder opposite the swivel
inlets between the side plates of
the ratchet link. (Refer to Dwg. 1)
5. Align the holes for the link retaining
pin and insert the pin through the side plates and cylinder to keep the units joined together.
Dwg. 1

4
PLACING THE TOOL IN SERVICE
3. After having turned the pump on and presetting the pressure for the correct torque, depress
the remote control button to advance the piston assembly. If the notch in the piston rod did not
engage the retract pin in the ratchet link when the link was joined to the housing, it will engage the
pin automatically during the rst advance stroke.
4. When the link is connected to the cylinder and the wrench is started, the reaction surface of the
wrench will move against the contact point and the nut will begin to turn.
5. When the nut is no longer turning and the pump gauge reaches the preset pressure, release
the remote control button. The piston rod will retract when the button is released. Under normal
conditions, an audible “click” will be heard as the tool resets itself.
6. Continue to cycle the tool until it “stalls” and the preset psi/torque has been attained.
7. Cycle the tool one last time to ensure full total torque.
MARINE MOLY GREASE
Lubrication frequency is dependent on factors known only to the user. The amount of contaminants in
the work area is one factor. Tools used in a clean room environment will obviously require less service
than a tool used outdoors and dropped in loose dirt or sand. Marine Moly Grease is formulated not to
wash out of the tool in areas where lubrication is critical. Whenever lubrication is required, lubricate as
follows:
1. Separate the low prole cylinder from the ratchet link if they are joined.
2. After wiping off the old grease, apply a daub of Marine Moly Grease to the hooking notch on the
piston rod and wipe a lm of Marine Moly Grease onto the sides and faces of the two sliders.
3. Disassemble the ratchet link as instructed in the Maintenance Section and wash the components
in a suitable cleaning solution in a well ventilated area.
4. Dry the components, then wipe a lm of Marine Moly Grease onto the wear surface of both side
plate sleeves and the hubs of the ratchet.
5. Spread a light lm of Marine Moly Grease onto the inner faces of both side plates covering the
area where the drive plate and drive segment travel. DO NOT pack the teeth of the drive segment
or ratchet with lube. It can prevent the teeth from engaging properly.
6. Reassemble the ratchet link as instructed in the Maintenance Section.
LUBRICATION

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TX Series Wrench Technical & Dimensional Data
Model Number TX-1 TX-2 TX-4 TX-8
Min. Torque (ft/lbs) 45 192 395 830
Max. Torque (ft/lbs) 560 1928 3950 8630
Min. Torque (nm) 61 260 535 1125
Max. Torque (nm) 759 2614 5355 11699
Output Accuracy +/-3% +/-3% +/-3% +/-3%
Repeatability 100% 100% 100% 100%
Duty Cycle 100% 100% 100% 100%
Cylinder Weight (lbs/kg) 1.0/0.5 3.5/1.6 6.0/2.7 11.7/5.0
Link Weight (lbs) 1.0-1.0 2.4-3.5 5.4-7.6 11.9-14.5
(kg) 0.45-0.45 1.0-1.5 2.4-3.4 5.5-6.5
Length (in/mm) 4.37/111.0 6.45/163.8 7.87/199.9 10.18/258.6
Width (in/mm) 0.78/19.8 1.25/31.8 1.63/41.4 2.05/52.1
Radius (in/mm) 0.23/5.8 0.36/9.1 0.46/11.7 0.54/13.7
Height (in/mm) 3.25/82.6 4.00/101.6 5.60/142.2 7.00/177.8
Hex Range From 1/2”/13mm 3/4”/19mm 1”/27mm 1 7/8”/49mm
Hex Range To 2”/50mm 2 9/16”/65mm 3 1/8”/80mm 4 5/8”/120mm

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TX Series Wrench Technical & Dimensional Data
Model Number TX-16 TX-32 TX-45
Min. Torque (ft/lbs) 1560 3220 4850
Max. Torque (ft/lbs) 16600 35650 47380
Min. Torque (nm) 2115 4365 6575
Max. Torque (nm) 22503 48327 64239
Output Accuracy +/-3% +/-3% +/-3%
Repeatability 100% 100% 100%
Duty Cycle 100% 100% 100%
Cylinder Weight (lbs/kg) 16.0/7.3 26.0/11.5 29.0/13.0
Link Weight (lbs) 21.0-28.0 29.0-39.5 29.0-39.5
(kg) 9.5-13.0 13.0-17.9 13.0-17.9
Length (in/mm) 12.93/328.4 15.80/401.3 16.75/425.5
Width (in/mm) 2.50/63.5 3.24/82.3 4.88/124.0
Radius (in/mm) 0.65/16.5 0.93/23.6 0.93/23.6
Height (in/mm) 7.58/192.5 9.50/241.3 10.28/261.1
Hex Range From 2 3/16”/55mm 3 1/8”/80mm 3 1/8”/80mm
Hex Range To 5 5/16”/135mm 7 7/8”/200mm 7 7/8”/200mm

7

 
TX-1 Torque Conversion Chart ( Imperial )
I mp erial Conversion I mp erial Conversion I mp erial Conversion
PSI Ft-lbs PSI Ft-lbs PSI Ft-lbs
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     
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C  
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     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

8

• unur
TX-1 Torque Conversion Chart ( Metric )
M e t ri c Conversion M e t ri c Conversion M e t ri c Conversion
Bar Nm Bar Nm Bar Nm
     
     






     
     
     
     
     
     
     
     
     
     
     
     
     
     
E   E   E  
E   E   E  
 
N    
I     I  
  N    
     

  

C   C   C  
  

  

  

X   X   X  
  
I
  
I
  
I
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

9

10

11

12

13

• unur
TX-8 Torque Conversion Chart ( Imperial)
I mp erial Conversion I mp erial Conversion I mp erial Conversion
PSI Ft-lbs PSI Ft-lbs PSI Ft-lbs
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
 
  
 
  

 
  
  
   

  

        
        
  

 
  
  

  

  
  
  

  
  

  
 
C      C  
  

C  

  

X      X  
  
I
X  

  
I
  I    
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

14

• unur
TX-8 Torque Conversion Chart ( Metric )
M e t ri c Conversion M e t ri c Conversion M e t ri c Conversion
Bar Nm Bar Nm Bar Nm
     
     






     
     
     
     
     
     
     
     
     
     
     
     
     
 
E  
E  
0  

I  

 
 
E  
E  
0  

 
  
E  
 
E  
 
  
I
  

  
C  
  

  

C  
  

  
 
  

X  
  
I
 
X  
  
I
 
X  
  
 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

15

• unur
TX-16 Torque Conversion Chart ( Imperial )
I mp erial Conversion I mp erial Conversion I mp erial Conversion
PSI Ft-lbs PSI Ft-lbs PSI Ft-lbs
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
      
  

  
  

I  
 
  

  

  
  
  
  

I  
  
  

  
  
 
 
 

  
 
  

 
  
  

C  

  
 

  
  

 
C
  

  
  
  
I
I  
 
  
I 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

16

• unur
TX-16 Torque Conversion Chart ( Metric )
M e t ri c Conversion M e t ri c Conversion M e t ri c Conversion
Bar Nm Bar Nm Bar Nm
     
     






     
     
     
     
     
     
     
     
     
     
     
     
     
E  
 
E  
0
0  
  
I
  

E  
E  
  
  

 

 

E  
E  
  
 

I  
  

  
  
  

X  
  
I  
  
  
C  

  
X  

I  
  
  
C  

  
X  

I  
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

17

• unur
TX-32 Torque Conversion Chart ( Imp eria l )
I mp erial Conversion I mp erial Conversion I mp erial Conversion
PSI Ft-lbs PSI Ft-lbs PSI Ft-lbs
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
  
�  

  
 
�
  
  

  
�
 
 
  
  
�
  
  
  

C  
  

X  
  
I
 
  
  
�
  
  
  

  
C  

  
X  

I  
  
  
�  

  
  
 
C
 

X  
  
I 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

18

• unur
TX-32 Torque Conversion Chart ( Metric )
M e t ri c Conversion M e t ri c Conversion M e t ri c Conversion
Bar Nm Bar Nm Bar Nm
     
     






     
     
     
     
     
     
     
     
     
     
     
     
     
E  
 
E  
  
  
I
0  

E  
E  
  
  

 
0
N  

E  
E  
0  
0  
N
I  

  
  
  
  

X  
  
I  
  
  
C  

  
X  

I  
  
  
C  

  
X  

I  
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.

19

• unur
TX-45 Torque Conversion Chart ( Imp eria l )
I mp erial Conversion I mp erial Conversion I mp erial Conversion
PSI Ft-lbs PSI Ft-lbs PSI Ft-lbs
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
  
�  

  
 
�
  
  

  
�
 
 
  
  
�
  
  
  

C  
  

X  
  
I
 
  
  
�
  
  
  

  
C  

  
X  

I  
  
  
�  

  
  
 
C
 

X  
  
I 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
For reference purposes only, please consult the calibration chart specific to your purchase or rental tool.