Torq Fusion GT1300PSS User manual

MODEL GT1300PSS
USER MANUAL
®
PNEUMATIC
TORQUE
WRENCH

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INTRODUCTION
Than you for choosing TORQ Fusion as your torque tool
manufacturer. We understand that our customers have many
options when selecting their equipment and we truly appreciate
the opportunity to serve your bolting needs.
Our company firmly believes that the development of any product
starts with first understanding the needs of our customers and
apprehending the challenges they encounter with the equipment
they currently use. The TORQ Fusion design team then tac les
these challenges and implements innovative resolutions in the
design it develops. Next we prototype and evaluate our designs
gauging not only performance, but also robustness. Every one of
our designs goes through an exhaustive life test ta ing into
account every possible situation that might occur during normal
operation. As our tools enter the production phase, each unit is
calibrated throughout its operating range and our technical staff
reviews each calibration certificate before signing off and
releasing it.
Please ta e the time to review the rest of this manual, paying
special attention to the safety instructions associated with your
equipment.
If you have additional questions please feel free to contact your
sales representative or the factory by email at info@torqfusion com .
Than you again for choosing TORQ Fusion!

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TABLE OF CONTENTS
INTRODUCTION .....................................................................................................3
TABLE OF CONTENTS ............................................................................................4
SAFETY.....................................................................................................................5
PPE – (Personal Protective Equipment).......................................................................5
WARRANTY.............................................................................................................6
ABOUT THE TOOL ..................................................................................................7
ABOUT THE FRL.......................................................................................................9
INSTALLATION ......................................................................................................11
OPERATING INSTRUCTIONS................................................................................12
REMOVING AND INSTALLING THE TOOL EXTENSION................................................13
REMOVING AND INSTALLING THE REACTION ARM..................................................13
REMOVING AND INSTALLING THE OUTPUT DRIVE.....................................................15
INSTALLING THE IMPACT SOCKET................................................................................16
DETERMINING THE SET PRESSURE.................................................................................17
LINEAR INTERPOLATION................................................................................................18
ADJUSTING THE SET PRESSURE .....................................................................................19
TIGHTENING ...................................................................................................................20
LOOSENING...................................................................................................................21
BEST PRACTICES ............................................................................................................22
CARE AND MAINTENANCE ...............................................................................22
TORQUE TOOL...............................................................................................................22
FRL - CLEANING THE FILTER ..........................................................................................23
FRL - ADDING TOOL OIL...............................................................................................23
FRL – REPLACING THE BATTERY ...................................................................................24
TOOL CALIBRATION............................................................................................25
TROUBLESHOOTING............................................................................................26
TOOL SPECIFICATION .........................................................................................27
PARTS & ACCESSORIES ......................................................................................28
DIMENSIONS ........................................................................................................28
GT1300PSS......................................................................................................................28
FRL...................................................................................................................................29
TABLE OF FIGURES...............................................................................................30

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SAFETY
Safety is our primary concern and we want to ensure that our
customers enjoy the benefits of our tools while observing all
appropriate safety measures. Our tools are designed to be
operated by trained, s illed personnel.
Never disassemble or modify any portions of the tool or the FRL
supplied by TORQ Fusion – doing so may result in personal injury
and the product warranty to become void. Never stri e or force
any portion of the torque wrench or the FRL as this may cause
damage to the equipment, create an unsafe situation and void
the warranty.
Reading this manual in its entirety is mandatory prior to
operating the equipment described in it. Additional training may
be required by your company’s training or safety advisor.
PPE – (Personal Protective Equipment)
Always wear protective eyewear when operating power
tools or entering an industrial environment.
Always wear hearing protection when operating power
tools or environmental conditions may exceed 85 dB(A) of noise.
Never place your hands or other body parts near the
reaction arm or any moving component – avoid pinch points.
It is a good practice to also wear wor gloves, a hard hat, steel toe
shoes and any other protective equipment suitable for the tas
being performed. Please consult with your company’s safety
advisor for more information.

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WARRANTY
TORQ Fusion LLC is proud to offer a one year limited warranty for
your torque wrench and FRL assembly. We are confident in and
stand behind all of the products we manufacture and sell.
TORQ Fusion LLC warrants this product against all material and
wor manship defects for the duration specified above from the
date of initial purchase. In the event that this product is found to
be defective after being examined by TORQ Fusion LLC and in
accordance with the terms specified in this section, the defective
product will be repaired or replaced, at the discretion of TORQ
Fusion LLC without cost to the end user.
The following list of reasons (investigated and assessed by TORQ
Fusion LLC) will cause this warranty to become void and null in its
entirety:
1. Any modifications, previous repairs or attempted repairs
performed by parties other than TORQ Fusion LLC or factory
authorized repair facilities.
2. Any visible mar s or signs indicating the equipment has
been abused or mishandled, other than normal wear of
the equipment.
3. Improper maintenance of the equipment according to the
instructions in this manual.
This warranty covers all the equipment supplied except:
1. Pac aging materials
2. The output drive
3. The reaction arm
4. Consumables: batteries, lubricating oil, etc.
TORQ Fusion LLC shall in no event be found liable for any damages
including personal or material, including loss of profits of any
parties involved.
Please contact your sales representative or the factory directly
with any questions you may have regarding this warranty.

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ABOUT THE TOOL
The GT1300PSS is a single speed pneumatic torque wrench
designed to output a maximum of 1300 ft-lbs (1,763 N-m) of
continuous torque. The tool is based on a multi-vane pneumatic
motor driving a high reduction multi-stage planetary gearbox.
When tightening or loosening fasteners requiring torque in the
range offered by this tool, there are many other methods
available: large brea er bars, manual torque multipliers, impact
wrenches or hydraulic wrenches. Brea er bars and manual torque
multipliers are the lowest cost option, but are labor intensive and
some have questionable torque accuracy. Impact wrenches are
relatively low cost, but have very poor torque accuracy and
generate a large amount of vibration and noise – these factors
may present serious health ris s. Hydraulic wrenches are very
expensive, move relatively slow and require heavy hydraulic
pumps. Continuous torque pneumatic wrenches li e this one offer
a good balance of power, speed, ergonomics and cost.
Figure 1 - FRONT VIEW OF TOOL
Reaction arm
Gearbox
Replaceable output
drive
Air flow adjustment
(disabled)
Air exhaust
Swivel air
connection
Trigger

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Figure 2 - BACK VIEW OF TOOL
Direction lever
Serial number
label
Cushioned grip

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ABOUT THE FRL
The rotary vane motor of the tool produces a torque output
proportional to the air pressure it is supplied. In order to facilitate
adjustment of the torque output of the tool we supply a
designated FRL (Filter/Regulator/Lubricator) with each one.
To ensure that the torque output of this tool is as accurate as
possible, our FRL features a precision grade regulator and digital
pressure gauge. It is imperative that our tools only be operated
with the FRL units supplied by TORQ Fusion and the serial number
printed on the torque chart of the FRL matches the serial number
printed on the bac of the tool.
Figure 3 - FRONT VIEW OF FRL
Carry
handle
Pressure
gauge
Torque
chart
Air inlet
Battery
drawer
Swivel fitting
Air hose
Quic start
instructions
Lubricator
Air pressure
adjustment
Tool storage
compartment

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Figure 4 - BACK VIEW OF FRL
Figure 5 - BOTTOM VIEW OF FRL
Swivel fitting
Air Hose
Rubber
feet
Hose
storage
Tool
storage
Lubricator
Filter
Regulator

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INSTALLATION
Installation of this tool must be performed by personnel s illed
and trained in the installation of pneumatic fittings.
The air supply will be connected to the FRL air inlet connection
(see Figure 3) via a pneumatic hoo -up hose (not supplied) with a
minimum inside diameter of ½” or larger depending on the
distance from the compressor to the FRL. It is the responsibility of
the end user to ensure that a minimum air supply of 20 CFM @ 115
PSI is delivered to the inlet connection of the FRL. Regardless of
hoo -up hose size used, it must have a ½” MNPT fitting entering the
FRL. The installation of a shut-off valve is also recommended
upstream of the FRL.
Teflon tape must be used on the ½” MNPT fitting prior to installing it
to the FRL – TORQ Fusion does not recommend the use of any
other type of thread sealer. Proper torque for that size fitting must
be applied (50-60 ft-lbs [68-81 N-m] is common practice). No
bac up wrench is required for installation as the FRL housing will
perform that function.
Un-coil the hose supplied with the FRL and connect the free end to
the swivel air connection at the base of the tool handle (see Figure
1). To engage the fittings simply push the female fitting into the
male fitting while sliding bac the nurled sleeve on the female
fitting – this is performed easier with the system de-pressurized but it
may also be done under pressure.
To ensure sufficient air flow is being supplied to the tool, set the FRL
to the maximum pressure expected to be used – do not set FRL to
a pressure higher than indicated on the torque chart. Install a
soc et onto the tool and use the tool to tighten a fastener until the
tool stops turning; while still depressing the tool trigger chec the
digital pressure gauge on the FRL and ensure the pressure
displayed is within 1 psi of the pressure set at the beginning of this
paragraph. If the pressure drops more than 1 psi a larger
pneumatic hoo -up hose and/or compressor is needed.
The torque tool is now installed.

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OPERATING INSTRUCTIONS
Before starting completely read this manual and ensuring all steps
are understood. Any additional questions may be answered by
contacting your sales representative or the factory by email at
info@torqfusion com .
Ensure that the serial number on the bac of the tool (see Figure 2)
matches the serial number on torque chart located on the FRL
(see Figure 3).
Only ¾” or 1” impact soc ets may be used with your torque tool,
properly installed with loc ing pins and retainer ring (see Figure 9).
The tool is normally supplied with a ¾” square output drive, unless a
1” square output drive was specified when purchased or
purchased separately. To change the size of the square drive see
REMOVING AND INSTALLING THE OUTPUT DRIVE section later in this
manual.
Figure 6 - IMPACT SOCKET
A reaction arm is necessary for the operation of the tool in order to
eep the gearbox housing from turning under extreme torque
output conditions. While operating, the reaction arm must be
resting against a robust stationary object (usually a nearby
fastener) capable of withstanding a reaction force equal to the
torque being generated by the tool. During operation the tool
handle may be rotated with respect to the gearbox housing as not
to transmit a reaction torque greater than a few foot pounds to
the operator of the tool.

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REMOVING AND INSTALLING THE TOOL EXTENSION
Your tool may be equipped with an optional extension depending
on your application. The tool extension may be easily removed
and re-installed for increased tool versatility. It can be installed in
one of 8 positions on the spline of the gearbox housing (see Figure
7). To install remove the set-screw located on the tool extension
using a 1/8” hex wrench. Slide out the tool extension retaining pin –
if the retaining pin does not slide out easily, it may be pushed out
with the 1/8” hex wrench. Ensure that the inside of the gearbox
receptacle is well lubricated as shown using lithium or petroleum
based grease. It is also a good practice to chec the lubrication
on the extension journal by sliding out the inner shaft of the
extension – lubricate using lithium or petroleum based grease and
re-insert the inner shaft into the extension housing. Fully engage the
spline of the tool extension with the spline of the gearbox housing
and insert the tool extension retaining pin. Replace the setscrew in
the tool extension and re-tighten.
Figure 7 – TOOL EXTENSION INSTALLATION
To remove the tool extension, remove the set screw and tool
extension retaining pin, then slide the extension off the gearbox. Be
careful not to drop the inner shaft out of the assembly.
REMOVING AND INSTALLING THE REACTION ARM
Reaction arm
retaining pin
Setscrew
Gearbox
housing
spline
Lubricate
well
Extension
journal

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The reaction arm may be installed in one of 8 positions on the
spline of the gearbox housing (see Figure 8). To install remove the
set-screw located on the reaction arm using a 1/8” hex wrench.
Slide out the reaction arm retaining pin – if the retaining pin does
not slide out easily, it may be pushed out with the 1/8” hex wrench.
Ensure that the output drive journal is well lubricated as shown
using lithium or petroleum based grease. Fully engage the spline of
the reaction arm with the spline of the gearbox housing and insert
the reaction arm retaining pin. Replace the setscrew in the
reaction arm and re-tighten.
Figure 8 - REACTION ARM INSTALLATION
To remove the reaction arm, remove the set screw and reaction
arm retaining pin, then slide the reaction arm off the gearbox.
Reaction arm
retaining pin
Setscrew
Gearbox
housing
spline
Reaction
arm spline
Lubricate
well

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REMOVING AND INSTALLING THE OUTPUT DRIVE
The output drive (square drive) of the torque wrench is designed to
be field replaceable by the operator. Some of the reasons for
changing the output drive could be replacing the standard ¾”
square drive with the optional 1” square drive, replacing a bro en
output drive or replacing the standard output drive with a custom
output drive. Regardless of the reason for replacing the output
drive, it’s as easy as removing one set screw.
Start by removing the reaction arm – see “REMOVING AND
INSTALLING THE REACTION ARM” in the previous pages. Continue
by simply pulling the square drive out.
Figure 9 – OUTPUT DRIVE INSTALLATION
If removing a bro en output drive the part should just slide out – if it
doesn’t, a pair of pliers or screw driver may be used.
To re-install an output drive, first lubricate the output drive journal
and quadrilobe areas as shown using a lithium or petroleum based
grease, engage output drive to gearbox and replace reaction
arm - see “REMOVING AND INSTALLING THE REACTION ARM” in the
previous pages.
Lubricate well

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INSTALLING THE IMPACT SOCKET
Only impact soc ets must be used with your torque tool. They must
be properly installed with loc ing pins and retainer ring. The output
drive of your tool may be either ¾” or 1” depending on how the
tool was ordered or what additional accessories were purchased
with it.
First slide the retainer ring (o-ring) over the soc et as shown in
Figure 10.
Figure 10 - IMPACT SOCKET
Place the soc et over the torque tool output drive (square drive)
aligning the loc ing pin hole with the hole in the output drive. Slide
in the loc ing pin (see Figure 11).
Figure 11 - SOCKET INSTALLATION
Finish the soc et installation by rolling the retainer ring into the
soc et groove to eep the loc ing pin in place.
Loc ing pin hole
Retainer ring
Loc ing pin
Soc et groove

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DETERMINING THE SET PRESSURE
The GT1300PSS is capable of operating under a wide range of
pressures, not exceeding 100 PSI. The toque output of the tool will
increase as the pressure on the FRL is set to higher values.
Based on the size and application of the fastener being tightened,
determine the appropriate torque required. Correlate the required
torque to the operating pressure by loo ing at the torque chart
located on the FRL (see Figure 3). The torque chart lists pressure
values in increments of 5 PSI. For most applications if you cannot
find the exact torque value on your chart, the closest value will do
– if more precise values are needed use one of the formulas on the
next page to calculate the set pressure.
The chart below is a sample of what the torque chart on your FRL
might loo li e. DO NOT use these values to set the pressure for
your tool, instead use the values on the chart provided with your
FRL.
Figure 12 - SAMPLE TORQUE CHART

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LINEAR INTERPOLATION
Intermediate (interpolated) values may be calculated using linear
interpolation in order to maintain a high level of accuracy for your
tool.
Example: To set the tool at 650 ft-lbs when that value is not listed
on your chart use the following formula to determine the set
pressure for the FRL:
( ) ( )
psi
TT
PP
TTPP
abovebelow
abovebelow
aboveabove
9.76
636673
7580
63665075 ≈
−
−
×−+=
−
−
×−+=
Figure 13 - CHART FOR INTERPOLATION EXAMPLE
A simpler but less accurate formula may also be used:
psiP
T
T
P
above
above
7.7675
636
650 ≈×=×=
P
below
P
above
T
above
T
below
650 would fall
between these
lines
Where:
P = set pressure for FRL
T = torque to achieve

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ADJUSTING THE SET PRESSURE
Once the appropriate set pressure has been determined from the
torque chart and/or by using the information in the previous
sections, power on the pressure gauge and turn the air pressure
adjustment nob (see Figure 12) until the set pressure is achieved.
Always turn the nob clockwise to the set pressure. If the pressure is
too great turn the nob counter-cloc wise until below set pressure
and then cloc wise bac up to set pressure.
Always ma e sure that the units displayed on the digital
pressure gauge match the units on the torque chart.
The motor must not be running while setting the pressure.
The tool may or may not be engaged with the fastener to be
tightened while adjusting the set pressure.
Figure 14 - PRESSURE SETTING
Air pressure adjustment
Torque chart
Pressure gauge

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TIGHTENING
Once the reaction arm and appropriate size impact soc et have
been installed and the correct pressure for your application has
been set, you are ready to tighten your fastener. Depending on
your application, you may be required to use lubrication on the
nut being tightened and a bac up wrench on the nut on the
opposite end of the stud – please consult the instructions supplied
by the fastener manufacturer or the engineering instructions
supplied for the project.
Be sure to wear appropriate PPE (Personal Protective
Equipment) – please see the sections on “SAFETY” and “PPE” at the
beginning of this manual. Never place your hands or other body
parts near the reaction arm or any moving component.
Set the direction lever of the tool to “R”. Place the impact soc et
over the fastener (see Figure 15). Slowly depress the tool trigger
until the reaction arm touches a robust, stationary object li e a
nearby fastener or other similar metal feature (see Figure 16).
Remember that the gearbox and reaction arm assemblies can
rotate with respect to the tool handle to accommodate the most
favorable wor angle for the tool.
Figure 15 - SOCKET OVER FASTENER Figure 16 - REACTION ARM AGAINST
NEARBY FASTENER
Fully depress trigger until soc et stops turning. Once the soc et
stops do not depress the trigger again – doing so may increase the
torque applied to the fastener by an undesirable amount. If
necessary set the direction lever of the tool to “L” and depress the
trigger slightly to ease in disengagement of soc et.