XXI/Avanti/Stealth SERIES Operational Manual July 2004
Table of Contents XXI/Avanti/Stealth SERIES Operational Manual SECTION I IMPORTANT SAFETY INSTRUCTIONS SECTION II BEFORE USE 2-1 Working Pressure 2-2 Hydraulic Connections 2-3 Electrical Connections 2-4 Air Connections SECTION III OPERATION 3-1 General 3-2 Connecting the System 3-3 Drive Direction Change 3-4 Reaction Arm XXI/Avanti 3-5 Setting Torque 3-6 Setting Pump Pressure 3-7 Tightening Procedures 3-8 Operating the XXI, Avanti & Stealth Systems 3-9 Loosening Procedures SECTTION IV 4-1 Tool set up a
INTRODUCING THE NEW GENERATION HYTORC Thank you for buying the NEW HYTORC FREEDOM-LINE! This manual is designed to provide you with the basic knowledge required to operate and maintain your HYTORC bolting equipment. Please read this manual carefully and follow the instructions provided. If you have any questions regarding HYTORC bolting equipment, please call us at 201-512-9500 or contact us at hytorsales@hytorc.com.
INTRODUCTION HYTORC tools are uniquely multi-purpose. They can be used as accurate bolting equipment on conventional nuts in open or confined spaces. They also can be used as reaction arm free tensioning equipments, when used with HYTORC LoaDISC washer or HYTORC-Clamp, Hydraulically Actuated Mechanical Tensioner. SECTION I IMPORTANT SAFETY INSTRUCTIONS HYTORC tools are designed for the safety of operators.
SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous page2-3 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connectors. Extension cord up to 50 feet should be #10 AWG gauge.
SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC READ CAREFULLY: Most malfunctions, in new equipment, are the result of improper operation and/or set-up. PREPARATION: Remove HYTORC equipment from shipping container. INSPECTION: Visually inspect all components for any damage during transportation. If damages are found, notify HYTORC immediately.
SECTION II INSTRUCTIONS BEFORE USING YOUR NEW HYTORC -continued from the previous page2-3 ELECTRICAL CONNECTIONS Ensure proper power availability to prevent motor failure or dangerous electrical overloading. Compare the motor nameplate for required amperage. Do not use electric pump, if three prong electrical plug is not whole. Minimize the length of extension cords and be sure they are of adequate wire size, with ground connectors. Extension cord up to 50 feet should be #10 AWG gauge.
SECTION III OPERATION – Torquing Conventional Nuts 3-1 General All HYTORC tools are supplied completely assembled and are ready to use. A HYTORC Hydraulic Power Pack, for use with your HYTORC tools, is recommended to provide the speed, pressure and portability that makes your HYTORC SYSTEM more efficient and accurate. The SYSTEM accuracy of your HYTORC tool is +-3% based upon manufacturer’s specifications.
SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-3 Drive Direction Change Avanti tools To remove the square drive, disengage the drive retainer assembly by depressing the retaining round button and gently pulling on the square end of the square drive. The square drive will slide out. To insert the drive in the tool, place the drive in the desired direction, engage drive spline and ratchet spline, then twist bushing until engage to the housing spline.
SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-5 Setting Torque Once the SYSTEM is fully connected and the proper power supply is available, it is time to adjust the pump pressure to the level needed on your job. When tightening, use the manufacturer’s specifications to determine the torque value ultimately required. Appendix I – which is presented as a guideline for comparison only – gives typical torque values specified for the most commonly encountered fasteners.
SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-7 Applying the Stealth – the Tightening Process 1. Once the target pressure is set (refer to 3-6) Cycle the tool several times to full pressure to assure proper operation. 2. Place the right side of the ratchet link directly over the nut. Ensuring the hex is fully engaged and the reaction pad portion of the link abuts solidly against an adjacent nut or other stationary object. (see 3-3 for proper tool placement) 3.
SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-8 Operating the Avanti and Stealth SYSTEMS Releasing “LOCKED-ON” tools. Should the tool “LOCK-ON” after the final cycle, slide the slider (or the lever on Avanti) with the pump off or in retract position. Turn the pump back on and while maintaining the pressure, cycle Avanti in the pump’s manual mode.
SECTION III OPERATION – Torquing Conventional Nuts -continued from the previous page3-9 Loosening Procedures Avanti and Stealth SYSTEM First, set the pump to 10,000PSI. Set the tools for the loosening mode (Refer to 3-3), assuring the reaction surface abuts squarely off a solid reaction point. Press and hold the remote control button down. Pressure will decrease as the socket begins to turn. As the cylinder extends fully, you will hear a “CLICK”.
SECTION IV OPERATION – HYTORC LoaDISC and Clamp 4-1 Tool Set up and Operation When used in conjunction with the HYTORC LoaDISC Washer or Clamp, the operation is essentially the same as with the conventional nuts, but with one notable exception: THERE ARE NO REACTION FORCES TO CONSIDER OR PROVIDE FOR! The reaction forces are absorbed through the fastener assembly itself. Each individual customer order for LoaDISC or Clamps will be provided with specific installation instructions for each application.
SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-2 HYTORC LoaDISC Tensioning 6. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until tool “STALLS OUT” 7. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B. Insure that joint faces are free from grease and oil.
SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-3 HYTORC LoaDISC De-tensioning 1. Set pump to maximum pressure. 2. Place tooling to disengage the nut and the LoaDISC with “LOOSENING” side facing the operator. 3. Verify proper socket engagement by momentarily pressurizing tool. If tool remains stationary, operate normally until the nut is loose. 4. Should tool rotate during initial pressurizing: A. Insure both socket and sleeve are fully engaged. B.
SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-4 HYTORC LoaDISC Lubrication Instruction & Trouble Shooting STEP 1: Make sure all threads and surfaces are free of dirt or grit. STEP 2: Apply spray lube TS801 moly spray to nut per procedure indicated below. Allow spray lube to dry (spray lube is shipped with LoaDISC order). Refer to the Dry-lube container label for a drying time.
SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-5 HYTORC Clamp Installation - Tensioning The HYTORC Clamp is provided with lubrication and is shipped ready for use. For re-lubrication, please refer to lubrication Instructions. (4-6) 1. Thread the Clamp down on the stud, turn the Puller Sleeve to contact the flange, contacting the flange or the spot face firmly. The Clamp should fit easily onto the spot face. 2.
SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-6 HYTORC Clamp Installation - Detensioning 1. Before using XXI or Avanti tool on the Clamp, make sure the tool and the drive member are set properly. The castellated drive and the splined reaction member should stick out on the left side for detensioning. Cycle the tool and the drive a few times to ensure that the tool is properly operating. Repeat this step only when you change the tool or the drive. 2.
SECTION IV OPERATION – HYTORC LoaDISC and Clamp -continued from the previous page4-7 HYTORC Clamp Lubrication Instruction The Clamp Lubrication Instructions: (Use a clean stiff bristle brush) STEP 1: Make sure all threads and splines are free of dirt or grit. Generously grease internal threads on the Jack-up Sleeve with a brush to get full coverage to the thread root. STEP 2: Generously grease external threads on the Puller Sleeve with a brush to get full coverage to the thread root.
SECTION V OPERATION – HYTORC Power Packs 5-1 HYOTRC Power Packs General Information All HYTORC Power Packs operate at a pressure range from 500 to 10,000 PSI and are fully adjustable. They have been engineered and designed for portability and high flow for increased speed.
SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-3 Prior to Use -ContinuedMake sure all desired gauge, valve, hose and quick coupler connections are tight and secure. The gauge permits the operator to monitor the load on the wrench. *Calibrated gauges are available for most application. Before starting your HYTORC pump, connect your hydraulic hoses to both the pump and torque wrench.
SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-5 Operation Air Pump To start the pump, depress the advance button and release it. This will put the tool in the retract mode. To advance the tool, depress the advance button and hold it down. When you are done, depress the stop button and the motor will stop. NOTE: The pump is still pressurized.
SECTION V OPERATION – HYTORC Power Packs -continued from the previous page5-7 Starting with automatic operation MANUAL MODE For manual operation, depress the Mode [M] 3-position rocker switch to the ‘MANUAL’ position. Hold down the Control [C] rocker switch in the ‘RUN’ position to advance the tool(s). The switch will toggle to the ‘NEUTRAL’ position when released, retracting the tool(s). Depress the Control [C] switch to the ‘OFF’ position to turn off the system.
