TorcUP TU-2 User manual

OPERATION AND MAINTENANCE
MODELS TU-2, TU-3, TU-7, TU-11, TU-20, TU-27 & TU-60
MANUAL
TU Series Hydraulic Torque Wrenches
TU Series
1025 Conroy Place, Easton, PA. 18040 * U.S.A.
Phone: [phone] * Fax: [phone]
Toll Free: 1-888-TORCUP-1
Email: [email protected] * Website: www.torcup.com

Operational and Maintenance Manual for TorcUP
TU-2, TU-3, TU-11, TU-20 ,TU-27 AND TU-60
Square Drive Hydraulic Torcque Wrenches
Version 1: 2015 February
Series TU-2, TU-3, TU-7, TU-11, TU-20, TU-27 and TU-60 Square Drive Hydraulic Torque Wrenches
are designed for installing and removing threaded fasteners requiring precise high torque during bolt
makeup and maximum torque during 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 require
ments 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 psig (681 bar) maximum pressure with this tool.
• Use only twin line hydraulic hose rated for 10,000 psig (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. Make certain the spring-loaded
retaining rings are fully engaged and the safety rings are tightly threaded against the spring-loaded retain
ing rings to prevent the connectors from disengaging under pressure.
• 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.
The use of other than genuine TorcUP replacement parts may result in safety
hazards, decreased tool performance, and increased maintenance, and may
invalidate all warranties. Repairs should be made only by authorized
personnel. Consult your nearest TorcUP Authorized Service Center.
Refer All Communications to the Nearest TorcUP Ofce or Distributor.
For Technical Support & Information Contact:
TorcUP Inc.
1025 Conroy Place, Easton, PA 18040 USA
Phone: [phone] Fax:[phone]
email: [email protected]
1/21

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 & 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 an 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 (TU-20, TU-27 or TU-60) 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 protective gear (i.e. Ear Protection, 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.
2/21

PLACING THE TOOL IN SERVICE
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. After making certain that they are fully engaged,
thread the safety rings tightly against the spring–loaded retainer rings.
2. Connect the opposite ends of the hose to the pump in the same manner.
ADJUSTMENTS
SETTING THE SQUARE DRIVE FOR ROTATION
The position of the square drive when looking toward the shroud will determine if the tool is
set to tighten or loosen the nut. When the square drive extends to the left when looking at
the shroud with the inlets away from you, the tool is set to loosen the nut. When the square
drive extends to the right, the tool is set to tighten the nut. To change the direction of rotation
for model TU-2 TU-3, TU-7 and TU-11 simply push the square drive into the housing until the
drive projects out the opposite side of the tool. For model TU-20,TU-27 & TU-60, loosen and
remove the square drive retaining screw and pull the square drive out of the housing. Insert
the square drive into the opposite side of the housing and secure it by installing the screw in
the splined end of the drive.
SETTING THE TORQUE
After determining the desired torque, use the calibration certicate provided with the tool to
determine the pressure necessary to achieve that torque. You may also refer to the chart
engraved on the shroud of the tool or the chart provided on page 7 of this manual.
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 thumb
screw. 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.
3/21

The function of a reaction device is to hold the tool in position against the forces generated to
tighten or loosen bolts or nuts. Hydraulic wrenches generate tremendous force.
SETTING THE REACTION ARM
An improperly
positioned reaction
arm may result in
operator injury
or damage tooling.
REACTION
CONTACT
POINTS
REACTION
CONTACT
POINTS
REACTION
CONTACT
POINTS
REACTION
CONTACT
POINTS
Square Drive Hydraulic Wrench Reaction Points (Dwg.01)
Make sure the reaction arm is positioned correctly.
(Refer to Dwg. 01).
The reaction arm can be positioned numerous
places within a 360O circle. However, for the arm to
be correctly positioned, it must be set within a 90O
quadrant of that circle. That quadrant is the area
located between the protruding square drive and
the bottom of the housing away from the swivel
inlets. It will always be toward the lower half of the
housing and on one side of the housing when
tightening and the other side when loosening.
4/21

OPERATING THE WRENCH
The position of the square drive relative to the shroud
determines whether the action will tighten or loosen the
nut. (Refer to Dwg. 02 for application examples).
The power stroke of the piston assembly will always
turn the square drive toward the shroud.
1. Place the square driver in the socket and the socket
on the nut. Make certain the square driver and socket
are the correct size for the nut and that the driver fully
engages the socket and the socket fully engages the
nut.
2. Position the reaction arm or surface against an
adjacent nut, ange or solid system component.
Make certain that there is clearance for the hoses,
swivels, inlets and end plug. DO NOT allow the tool
to react against the hoses, swivels, inlets or end plug.
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.
4. When the wrench is started, the reaction surface of the wrench or reaction arm 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
and 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. Once the nut stops rotating, cycle the tool one last time to achieve total torque.
Square Drive Position for Loosening and Tightening(Dwg.02)
5/21

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 out-doors 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. Remove the drive plate, ratchet, drive segment and sleeves as instructed in the
maintenance section and wash the components in a suitable cleaning solution in a well
ventilated area.
2. After drying the components, wipe a lm of Marine Moly Grease onto the wear
surface of both sleeves and the ends of the ratchet.
3. Spread a light lm of Marine Moly Grease onto the inner face and both sides of the Drive
Plate. Do not pack the teeth of the drive segment or ratchet with lube. It can prevent the
teeth from engaging properly.
4. Place a daub of Marine Moly Grease in the piston rod recess of the drive plate before
linking the piston rod to the drive plate at assembly.
CRITICAL LUBRICATION
It is imperative to lubricate the piston rod recess of the drive plate to piston rod contact area
every 80 hours of continuous duty cycling.
Lubricate as follows:
1. Remove shroud screws, shroud, and roll pin.
2. Pry the drive plate assembly forward from the piston rod to expose the recessed
contact area in the drive plate.
3. With a rag, wipe clean the area and apply a sizeable amount of Marine Moly Grease.
4. Reassemble as instructed in the maintenance section.
LUBRICATION
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TU Series Torque Conversion Chart
P.S.I TU-2 TU-3 TU-7 TU-11 TU-20 TU-27 TU-60 Bar TU-2 TU-3 TU-7 TU-11 TU-20 TU-27 TU-60
.-lbs. .-lbs. .-lbs. .-lbs. .-lbs. .-lbs. .-lbs. N.M N.M N.M N.M N.M N.M N.M
1,000 132 347 790 1198 2249 3032 6202 69 179 470 1071 1624 3049 4111 8409
1,200 159 414 947 1433 2683 3606 7422 83 215 561 1284 1943 3638 4889 10062
1,400 185 481 1104 1668 3118 4180 8641 97 251 652 1497 2262 4227 5668 11716
1,600 212 547 1262 1904 3552 4755 9861 110 287 742 1710 2581 4816 6446 13369
1,800 238 614 1419 2139 3987 5329 11080 124 323 833 1924 2900 5405 7225 15023
2,000 265 681 1576 2374 4421 5903 12300 138 359 923 2137 3219 5994 8003 16677
2,200 292 748 1734 2612 4847 6469 13477 152 396 1015 2351 3541 6572 8771 18272
2,400 319 816 1892 2850 5273 7035 14654 165 433 1106 2565 3864 7150 9538 19868
2,600 346 883 2050 3088 5700 7600 15831 179 469 1197 2779 4187 7728 10305 21464
2,800 373 951 2208 3326 6126 8166 17008 193 506 1289 2994 4509 8305 11072 23060
3,000 400 1018 2366 3564 6552 8732 18185 207 542 1380 3208 4832 8883 11839 24656
3,200 427 1085 2525 3802 6974 9302 19378 221 579 1471 3423 5155 9455 12612 26273
3,400 454 1152 2683 4041 7396 9873 20571 234 616 1562 3638 5479 10028 13386 27890
3,600 481 1220 2842 4279 7818 10443 21763 248 652 1654 3853 5802 10600 14159 29507
3,800 508 1287 3000 4518 8240 11014 22956 262 689 1745 4068 6125 11172 14932 31124
4,000 535 1354 3159 4756 8662 11584 24149 276 725 1836 4283 6448 11744 15706 32742
4,200 561 1421 3317 4990 9077 12137 25344 290 761 1926 4497 6766 12306 16455 34361
4,400 588 1487 3475 5225 9492 12690 26538 303 797 2016 4711 7084 12869 17205 35981
4,600 614 1554 3632 5459 9906 13242 27733 317 833 2107 4925 7402 13431 17954 37601
4,800 641 1620 3790 5694 10321 13795 28927 331 869 2197 5139 7719 13994 18704 39220
5,000 667 1687 3948 5928 10736 14348 30122 345 904 2287 5353 8037 14556 19453 40840
5,200 694 1754 4106 6164 11158 14911 31317 359 941 2379 5568 8357 15128 20217 42460
5,400 721 1822 4265 6400 11580 15474 32511 372 977 2470 5782 8677 15700 20980 44079
5,600 747 1889 4423 6635 12002 16037 33706 386 1013 2561 5997 8996 16273 21743 45699
5,800 774 1957 4582 6871 12424 16600 34900 400 1050 2653 6212 9316 16845 22507 47319
6,000 801 2024 4740 7107 12846 17163 36095 414 1086 2744 6427 9636 17417 23270 48938
6,200 828 2092 4901 7348 13271 17720 37293 427 1123 2837 6645 9963 17993 24026 50562
6,400 855 2160 5063 7589 13696 18278 38491 441 1160 2929 6864 10290 18569 24781 52186
6,600 883 2229 5224 7831 14120 18835 39688 455 1197 3022 7083 10617 19145 25537 53810
6,800 910 2297 5386 8072 14545 19393 40886 469 1234 3114 7302 10944 19721 26293 55434
7,000 937 2365 5547 8313 14970 19950 42084 483 1270 3207 7521 11271 20297 27049 57058
7,200 964 2432 5705 8547 15388 20510 43282 496 1306 3297 7735 11588 20863 27807 58683
7,400 990 2499 5863 8781 15806 21069 44480 510 1343 3388 7949 11905 21430 28566 60307
7,600 1017 2565 6021 9015 16223 21629 45678 524 1379 3478 8163 12223 21996 29325 61931
7,800 1043 2632 6179 9249 16641 22188 46876 538 1415 3569 8378 12540 22562 30083 63555
8,000 1070 2699 6337 9483 17059 22748 48074 552 1451 3659 8592 12857 23129 30842 65180
8,200 1098 2769 6505 9727 17492 23308 49272 565 1488 3754 8820 13188 23716 31601 66804
8,400 1126 2838 6674 9971 17925 23868 50470 579 1526 3848 9048 13518 24302 32360 68428
8,600 1153 2908 6842 10214 18357 24427 51667 593 1564 3942 9277 13849 24889 33119 70052
8,800 1181 2977 7011 10458 18790 24987 52865 607 1601 4037 9505 14179 25476 33878 71676
9,000 1209 3047 7179 10702 19223 25547 54063 621 1639 4131 9733 14510 26063 34637 73300
9,200 1236 3115 7342 10943 19653 26106 55260 634 1676 4223 9954 14837 26645 35395 74922
9,400 1263 3183 7505 11184 20082 26665 56456 648 1713 4316 10175 15164 27228 36153 76544
9,600 1291 3251 7668 11426 20512 27225 57653 662 1750 4408 10396 15491 27810 36912 78167
9,800 1318 3319 7831 11667 20941 27784 58849 676 1787 4500 10617 15818 28393 37670 79789
10,000 1345 3387 7994 11908 21371 28343 60046 689 1824 4592 10838 16145 28975 38428 81411
P.S.I.- FT.-lbs Bar.N.M.
Disclaimer: Please consult the calibration chart specic to your purchase or rental tool.
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TU-2,3,7,11 Series Wrench
8/21

TU-20 Series Wrench
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