Torq Fusion GT Series User manual

GT SERIES USER MANUAL
GT200PSS
GT500PSS
GT800PSS
GT1300PSS
GT2600PSS
®
PNEUMATIC
TORQUE
WRENCH

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INTRODUCTION
Thank y u f r ch sing TORQ Fusi n as y ur t rque t l
manufacturer. We understand that ur cust mers have many
pti ns when selecting their equipment and we truly appreciate
the pp rtunity t serve y ur b lting needs.
Our c mpany firmly believes that the devel pment f any pr duct
starts with first understanding the needs f ur cust mers and
apprehending the challenges they enc unter with the equipment
they currently use. The TORQ Fusi n design team then tackles
these challenges and implements inn vative res luti ns in the
design it devel ps. Next we pr t type and evaluate ur designs
gauging n t nly perf rmance, but als r bustness. Every ne f
ur designs g es thr ugh an exhaustive life test taking int
acc unt every p ssible situati n that might ccur during n rmal
perati n. As ur t ls enter the pr ducti n phase, each unit is
calibrated thr ugh ut its perating range and ur technical staff
reviews each calibrati n certificate bef re signing ff and
releasing it.
Please take the time t review the rest f this manual, paying
special attenti n t the safety instructi ns ass ciated with y ur
equipment.
If y u have additi nal questi ns please feel free t c ntact y ur
sales representative r the fact ry at info@to qfusion.com .
Thank y u again f r ch sing TORQ Fusi n!

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TABLE OF CONTENTS
INTRODUCTION .....................................................................................................3
TABLE OF CONTENTS ............................................................................................4
SAFETY.....................................................................................................................6
PPE – (Pers nal Pr tective Equipment).......................................................................6
WARRANTY.............................................................................................................7
INSTALLATION ........................................................................................................8
ABOUT THE TOOL ..................................................................................................9
ABOUT THE FRL.....................................................................................................11
STANDARD MODEL.......................................................................................................11
inteliTORQ™ MODEL ....................................................................................................13
OPERATING INSTRUCTIONS................................................................................14
REMOVING AND INSTALLING THE TOOL EXTENSION................................................15
REMOVING AND INSTALLING THE REACTION ARM..................................................15
REMOVING AND INSTALLING THE OUTPUT DRIVE.....................................................17
REMOVING AND INSTALLING THE 2600 REACTION ATTACHMENT .........................18
INSTALLING THE IMPACT SOCKET................................................................................19
STANDARD FRL - DETERMINING THE SET PRESSURE ...................................................20
STANDARD FRL - LINEAR INTERPOLATION ..................................................................21
STANDARD FRL - ADJUSTING THE SET PRESSURE........................................................22
inteliTORQ™ FRL – ADJUSTING THE SET PRESSURE ....................................................23
inteliTORQ™ FRL – CHANGING THE ACTIVE TOOL...................................................24
inteliTORQ™ FRL – ADDING A NEW TOOL.................................................................24
inteliTORQ™ FRL – REMOVING A TOOL.....................................................................24
TIGHTENING ...................................................................................................................25
LOOSENING...................................................................................................................26
BEST PRACTICES ............................................................................................................27
CARE AND MAINTENANCE ...............................................................................27
TORQUE TOOL...............................................................................................................27
FRL - CLEANING THE FILTER ..........................................................................................28
FRL - ADDING TOOL OIL...............................................................................................28
FRL – REPLACING THE BATTERY ...................................................................................29
TOOL CALIBRATION............................................................................................30
TROUBLESHOOTING............................................................................................31

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TOOL SPECIFICATION.........................................................................................32
PARTS & ACCESSORIES ......................................................................................32
PARTS & ACCESSORIES ......................................................................................33
DIMENSIONS ........................................................................................................33
GT200PSS........................................................................................................................33
GT500PSS........................................................................................................................34
GT800PSS........................................................................................................................34
GT1300PSS......................................................................................................................35
GT2600PSS......................................................................................................................35
FRL – Standard and inteliTORQ™...............................................................................36
TABLE OF FIGURES...............................................................................................37

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SAFETY
Safety is ur primary c ncern and we want t ensure that ur
cust mers enj y the benefits f ur t ls while bserving all
appr priate safety measures. Our t ls are designed t be
perated by trained, skilled pers nnel.
Never disassemble r m dify any p rti ns f the t l r the FRL
supplied by TORQ Fusi n – d ing s may result in pers nal injury
and the pr duct warranty t bec me v id. Never strike r f rce
any p rti n f the t rque wrench r the FRL as this may cause
damage t the equipment, create an unsafe situati n and v id
the warranty.
Reading this manual in its entirety is mandat ry pri r t
perating the equipment described in it. Additi nal training may
be required by y ur c mpany’s training r safety advis r.
PPE – (Pe sonal P otective Equipment)
Always wear pr tective eyewear when perating p wer
t ls r entering an industrial envir nment.
Always wear hearing pr tecti n when perating p wer
t ls r envir nmental c nditi ns may exceed 85 dB(A) f n ise.
Never place y ur hands r ther b dy parts near the
reacti n arm r any m ving c mp nent – av id pinch p ints.
It is a g d practice t als wear w rk gl ves, a hard hat, steel t e
sh es and any ther pr tective equipment suitable f r the task
being perf rmed. Please c nsult with y ur c mpany’s safety
advis r f r m re inf rmati n.

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WARRANTY
TORQ Fusi n LLC is pr ud t ffer a one yea limited wa anty f r
y ur t rque wrench and FRL assembly. We are c nfident in and
stand behind all f the pr ducts we manufacture and sell.
TORQ Fusi n LLC warrants this pr duct against all material and
w rkmanship defects f r the durati n specified ab ve fr m the
date f initial purchase. In the event that this pr duct is f und t
be defective after being examined by TORQ Fusi n LLC and in
acc rdance with the terms specified in this secti n, the defective
pr duct will be repaired r replaced, at the discreti n f TORQ
Fusi n LLC with ut c st t the end user.
The f ll wing list f reas ns (investigated and assessed by TORQ
Fusi n LLC) will cause this warranty t bec me v id and null in its
entirety:
1. Any m dificati ns, previ us repairs r attempted repairs
perf rmed by parties ther than TORQ Fusi n LLC r fact ry
auth rized repair facilities.
2. Any visible marks r signs indicating the equipment has
been abused r mishandled, ther than n rmal wear f
the equipment.
3. Impr per maintenance f the equipment acc rding t the
instructi ns in this manual.
This warranty c vers all the equipment supplied except:
1. Packaging materials
2. The utput drive
3. The reacti n arm
4. C nsumables: batteries, lubricating il, etc.
TORQ Fusi n LLC shall in n event be f und liable f r any damages
including pers nal r material, including l ss f pr fits f any
parties inv lved.
Please c ntact y ur sales representative r the fact ry directly
with any questi ns y u may have regarding this warranty.

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INSTALLATION
Installati n f this t l must be perf rmed by pers nnel skilled
and trained in the installati n f pneumatic fittings.
The air supply will be c nnected t the FRL air inlet c nnecti n
(see Figure 3) via a pneumatic h k-up h se (n t supplied) with a
minimum inside diameter f ½” r larger depending n the
distance fr m the c mpress r t the FRL. It is the resp nsibility f
the end user t ensure that a minimum air supply f 20 CFM @ 115
PSI is delivered t the inlet c nnecti n f the FRL. Regardless f
h k-up h se size used, it must have a ½” MNPT fitting entering the
FRL. The installati n f a shut- ff valve is als rec mmended
upstream f the FRL.
Tefl n tape must be used n the ½” MNPT fitting pri r t installing it
t the FRL – TORQ Fusi n d es n t rec mmend the use f any
ther type f thread sealer. Pr per t rque f r that size fitting must
be applied (50-60 ft-lbs [68-81 N-m] is c mm n practice). N
backup wrench is required f r installati n as the FRL h using will
perf rm that functi n.
Un-c il the h se supplied with the FRL and c nnect the free end t
the swivel air c nnecti n at the base f the t l handle (see Figure
1). T engage the fittings simply push the female fitting int the
male fitting while sliding back the knurled sleeve n the female
fitting – this is perf rmed easier with the system de-pressurized but it
may als be d ne under pressure.
T ensure sufficient air fl w is being supplied t the t l, set the FRL
t the maximum pressure expected t be used – d n t set FRL t
a pressure higher than indicated n the t rque chart. Install a
s cket nt the t l and use the t l t tighten a fastener until the
t l st ps turning; while still depressing the t l trigger check the
digital pressure gauge n the FRL and ensure the pressure
displayed is within 1 psi f the pressure set at the beginning f this
paragraph. If the pressure dr ps m re than 1 psi a larger
pneumatic h k-up h se and/ r c mpress r is needed.
The t rque t l is n w installed.

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ABOUT THE TOOL
The GT series t l is a single speed pneumatic t rque wrench
designed t utput c ntinu us t rque. The t l is based n a multi-
vane pneumatic m t r driving a high reducti n multi-stage
planetary gearb x.
When tightening r l sening fasteners requiring t rque in the
range ffered by this t l, there are many ther meth ds
available: large breaker bars, manual t rque multipliers, impact
wrenches r hydraulic wrenches. Breaker bars and manual t rque
multipliers are the l west c st pti n, but are lab r intensive and
s me have questi nable t rque accuracy. Impact wrenches are
relatively l w c st, but have p r t rque accuracy and generate
a large am unt f vibrati n and n ise – these fact rs may present
seri us health risks. Hydraulic wrenches are m re expensive, m ve
relatively sl w and require heavy hydraulic pumps. C ntinu us
t rque pneumatic wrenches like the GT series ffer a g d
balance f p wer, speed, erg n mics and c st.
Figu e 1 - FRONT VIEW OF TOOL
Reacti n arm
Gearb x
Replaceable utput
drive
Air fl w adjustment
(disabled)
Air exhaust
Swivel air
c nnecti n
Trigger

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Figu e 2 - REAR VIEW OF TOOL
Directi n lever
Serial number
label
Cushi ned grip

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ABOUT THE FRL
STANDARD MODEL
The r tary vane m t r f the t l pr duces a t rque utput
pr p rti nal t the air pressure it is supplied. In rder t facilitate
adjustment f the t rque utput f the t l, we supply a
designated FRL (Filter/Regulat r/Lubricat r) with each ne.
T ensure that the t rque utput f this t l is as accurate as
p ssible, ur FRL features a precisi n grade regulat r and digital
pressure gauge. Bef re shipping a t l and regulat r package,
they calibrated t gether as a set t eliminate a p ssible err r
accumulati n. It is rec mmended that ur t ls nly be perated
with the FRL units supplied by TORQ Fusi n and the serial number
printed n the t rque chart f the FRL matches the serial number
printed n the back f the t l. This will yield the maximum
precisi n p ssible. Our FRLs may be set with ut the t l running as
the regulat rs will aut matically adjust the pressure t c mpensate
f r any fl w rate required by ur t ls.
Figu e 3 - FRONT VIEW OF FRL
Carry
handle
Pressure
gauge
T rque
chart
Air inlet
Battery
drawer
Swivel fitting
Air h se
Quick start
instructi ns
Lubricat r
Air pressure
adjustment
T l st rage
c mpartment

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Figu e 4 - BACK VIEW OF FRL
Figu e 5 - BOTTOM VIEW OF FRL
Swivel fitting
Air H se
Rubber
feet
H se
st rage
T l
st rage
Lubricat r
Filter
Regulat r

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inteliTORQ™ MODEL
TORQ Fusi n als ffers a m re techn l gically advanced FRL
designed t significantly reduce uncertainty and the p ssibility f
human err r. This m del has all the features f ur standard FRL
plus the ability f c nverting pressure int t rque f r y ur specific
t l and displaying the t rque values directly. This FRL uses RFID t
read the t rque chart digitally st red inside a t l and c nverts
the pressure it is set at int the c rresp nding t rque, displaying it
dynamically. This eliminates the p ssible err rs ass ciated with
reading t rque charts, interp lating exact values f r in-between
pressures and reading anal g pressure gauges. The inteliTORQ™
FRL can st re digital calibrati n charts and be used with up t 4
TOR Fusi n pneumatic t rque wrenches. It can als display
pressure values like a c nventi nal FRL.
Figu e 6 - inteliTORQ™ FRL
RFID t l
reader
2 line multi-
functi n display
Functi n butt ns

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OPERATING INSTRUCTIONS
Bef re starting c mpletely read this manual and ensuring all steps
are underst d. Any additi nal questi ns may be answered by
c ntacting y ur sales representative r the fact ry at
info@to qfusion.com .
Ensure that the serial number n the back f the t l (see Figure 2)
matches the serial number n t rque chart l cated n the
Standard FRL (see Figure 3) r n the display f the inteliTORQ™
FRL (see Figure 6).
Only impact s ckets may be used with y ur t rque t l, pr perly
installed with l cking pins and retainer ring (see Figure 12). The GT
series t l is n rmally supplied with a standard square drive, unless
a different size was specified r purchased separately. T change
the size f the square drive see “REMOVING AND INSTALLING THE
OUTPUT DRIVE” secti n later in this manual.
Figu e 7 - IMPACT SOCKET
A reacti n arm is necessary f r the perati n f the t l in rder t
keep the gearb x h using fr m turning under extreme t rque
utput c nditi ns. While perating, the reacti n arm must be
resting against a r bust stati nary bject (usually a nearby
fastener) capable f withstanding a reacti n f rce equal t the
t rque being generated by the t l. During perati n the t l
handle may be r tated with respect t the gearb x h using as n t
t transmit a reacti n t rque greater than several f t p unds t
the perat r f the t l.

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Extensi n
j urnal
REMOVING AND INSTALLING THE TOOL EXTENSION
Y ur t l may be equipped with an pti nal extensi n depending
n y ur applicati n. The t l extensi n may be easily rem ved
and re-installed f r increased t l versatility. It can be installed in
ne f 8 p siti ns n the spline f the gearb x h using. T install,
rem ve the set-screw l cated n the t l extensi n using a 1/8”
hex wrench. Slide ut the t l extensi n retaining pin – if the
retaining pin d es n t slide ut easily, it may be pushed ut with
the 1/8” hex wrench. Ensure that the inside f the gearb x
receptacle is well lubricated as sh wn using a lithium r petr leum
based grease. It is als a g d practice t check the lubricati n
n the extensi n j urnal by sliding ut the inner shaft f the
extensi n – lubricate using lithium r petr leum based grease and
re-insert the inner shaft int the extensi n h using. Fully engage the
spline f the t l extensi n with the spline f the gearb x h using
and insert the retaining pin. Replace the setscrew in the t l
extensi n and re-tighten.
Figu e 8 – TOOL EXTENSION INSTALLATION
T rem ve the t l extensi n, rem ve the set screw and retaining
pin, then slide the extensi n ff the gearb x. Be careful n t t dr p
the inner shaft ut f the assembly.
REMOVING AND INSTALLING THE REACTION ARM
Retaining pin
Setscrew
Gearb x
h using
spline
Lubricate
well
Extensi n
j urnal

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The reacti n arm may be installed in ne f 8 p siti ns n the
spline f the gearb x h using. T install, rem ve the set-screw
l cated n the reacti n arm using a 1/8” hex wrench. Slide ut the
retaining pin – if the retaining pin d es n t slide ut easily, it may
be pushed ut with the 1/8” hex wrench. Ensure that the utput
drive j urnal is well lubricated as sh wn using a lithium r
petr leum based grease. Fully engage the spline f the reacti n
arm with the spline f the gearb x h using and insert the retaining
pin. Replace the setscrew in the reacti n arm and tighten.
Figu e 9 - REACTION ARM INSTALLATION
T rem ve the reacti n arm, rem ve the set screw and reacti n
arm retaining pin, then slide the reacti n arm ff the gearb x.
Retaining pin
Setscrew
Gearb x
h using
spline
Reacti n
arm spline
Lubricate
well

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REMOVING AND INSTALLING THE OUTPUT DRIVE
The utput drive (square drive) f the t rque wrench is designed t
be field replaceable by the perat r. S me f the reas ns f r
changing the utput drive c uld be changing the square drive
size, replacing a br ken utput drive r replacing the standard
utput drive with a cust m utput drive. Regardless f the reas n
f r replacing the utput drive, it’s as easy as rem ving ne set
screw.
Start by rem ving the reacti n arm – see “REMOVING AND
INSTALLING THE REACTION ARM” in the previ us pages. C ntinue
by simply pulling the square drive ut.
Figu e 10 – OUTPUT DRIVE INSTALLATION
If rem ving a br ken utput drive the part sh uld just slide ut – if it
d esn’t, a pair f pliers r screw driver may be used.
T re-install an utput drive, first lubricate the utput drive j urnal
and quadril be areas as sh wn using a lithium r petr leum based
grease, engage utput drive t gearb x and replace reacti n
arm - see “REMOVING AND INSTALLING THE REACTION ARM” in the
previ us pages.
Lubricate well

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REMOVING AND INSTALLING THE 2600 REACTION
ATTACHMENT
If y u have purchased a GT2600PSS y u will be happy t kn w
that it can be used as b th a 2600 ft-lb and 800 ft-lb t l. T switch
between m des the 2600 reacti n attachment will need t be
rem ved r installed.
T detach the 2600 reacti n fixture use a 1/8” hex wrench t
rem ve the 2 setscrews and pins sh wn. Slide ff the reacti n
fixture and replace with an utput drive and reacti n arm – n w
the t l will perate as a GT800PSS.
Figu e 11 - 2600 REACTION FIXTURE REMOVAL/INSTALLATION
T change back t 2600 m de rem ve the reacti n arm and
utput drive and reinstall the 2600 reacti n fixture, securing it with
the 2 setscrews and pins previ usly rem ved. It may be necessary
t slightly r tate the 1-1/2” square drive f the reacti n fixture t
be able t re-install. Use a 1/8” hex wrench t secure the set
screws.
Always make sure that the serial number n the label f the
2600 reacti n fixture matches the serial number n the back f the
t l therwise the t que utput will be inc rrect.
Rem ve setscrews and pins
2600 reacti n fixture
serial number label
T l serial
number
label

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INSTALLING THE IMPACT SOCKET
Only impact s ckets must be used with y ur t rque t l. They must
be pr perly installed with l cking pins and retainer ring. The utput
drive f y ur t l may be ¾”, 1” r 1-1/2” depending n h w the
t l was rdered r what additi nal access ries were purchased
with it.
First slide the retainer ring ( -ring) ver the s cket as sh wn in
Figure 10.
Figu e 12 - IMPACT SOCKET
Place the s cket ver the t rque t l utput drive (square drive)
aligning the l cking pin h le with the h le in the utput drive. Slide
in the l cking pin (see Figure 11).
Figu e 13 - SOCKET INSTALLATION
Finish the s cket installati n by r lling the retainer ring int the
s cket gr ve t keep the l cking pin in place.
L cking pin h le
Retainer ring
L cking pin
S cket gr ve

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STANDARD FRL - DETERMINING THE SET PRESSURE
The GT series t l is capable f perating under a wide range f
pressures, n t exceeding the maximum pressure listed n the
t rque chart. The t que utput f the t l will increase as the
pressure n the FRL is set t higher values.
Based n the size and applicati n f the fastener being tightened,
determine the appr priate t rque required. C rrelate the required
t rque t the perating pressure by l king at the t rque chart
l cated n the FRL (see Figure 3). The t rque chart lists pressure
values in increments f 5 PSI. F r m st applicati ns if y u cann t
find the exact t rque value n y ur chart, the cl sest value will d
– if m re precise values are needed use ne f the f rmulas in the
next secti n t calculate the set pressure.
The chart bel w is a sample f what the t rque chart n y ur FRL
might l k like. DO NOT use these values t set the pressure f r
y ur t l, instead use the values n the chart pr vided with y ur
FRL.
Figu e 14 - SAMPLE TORQUE CHART