SPX TWLC Manual de usuario
Edition 3 - 04-01-2010 TWLC Low Clearance Hydraulic Torque Wrench Operation Manual
L F 10063 SPX Bolting Systems Page 1 of 17
ORIGINAL INSTRUCTIONS
TWLC LOW CLEARANCE HYDRAULIC
TORQUE WRENCH
OPERATION MANUAL
BOLTING SYSTEMS
BOLTING SYSTEMSBOLTING SYSTEMS
BOLTING SYSTEMS
3030 East Pasadena Freewa
Pasadena, Texas 77503
Tel: 713.472.2500 Fax: 713.472.2501
www.spxboltings stems.com
Edition 3 - 04-01-2010 TWLC Low Clearance Hydraulic Torque Wrench Operation Manual
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Index
1. Introduction
2. Technical Specifications
3. Power Requirements
4. Safety
5. Preparing the torque wrench for use
6. Operating the Torque wrench
7. General torquing Procedure
8. Maintenance and Servicing
9. Fault Finding Chart
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1. Introduction
The TWLC Low Clearance torque wrench is a ratchet type torque tool for hydraulically tightening nuts and
bolts. It comprises quick-change, interchangeable drive heads designed to fit directly around the nut, each
head specific to the nut size. It is powered using a 10,000psi hydraulic pump unit, the torque output from
the TWLC Low Clearance torque wrench being proportional to the pump pressure applied.
The main components of the TWLC Low Clearance torque wrench are illustrated in Fig.1 below.
Fig 1. TWLC LOW CLEARANCE Torque Wrench
SAFETY
The TWLC Low Clearance torque wrench is a high power hydraulic tool and we strongly recommend that
all users are fully trained and competent in the use of hydraulic torque wrench systems. Incorrect use of
the equipment or failure to follow any of the safety precautions included within this manual could lead to
serious Operator injury.
QUICK-CHANGE HEA
SWIVEL MANIFOL
BO Y
HY RAULIC
COUPLINGS
REACTION PA
HEA RELEASE PIN
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2. Technical Specifications
The following technical data is applicable to all TWLC torque wrenches:
MAXIMUM PRESSURE : Advance - 690 Bar (10,000psi)
Retract - 69 Bar (1,000psi)
OPERATING TEMP. LIMITS : -20°C to +40°C
HY RAULIC OIL TYPE : Grade 46 hydraulic oil
TWLC LOW CLEARANCE TORQUE WRENCH RANGE
Wrench Ref Head Size Range Torque Output Approx.
Weight
Min** Max
TWLC 2 1-1/4” – 2-3/8” (32 – 60) 189 lbft 1,575 lbft 3.5 kg
TWLC 4 1-1/2” – 3-1/8” (40 – 80) 477 lbft 3,975 lbft 7.0 kg
TWLC 8 2-1/4” – 3-7/8” (60 – 100) 954 lbft 7,950 lbft 11.0 kg
TWLC 15 2-9/16” – 4-5/8” (65 – 120) 1,782 lbft 14,850 lbft 19.0 kg
TWLC 30 3-1/8” – 6-1/8” (80 – 155) 3,456 lbft 28,800 lbft 38.0 kg
** Note that minimum torque can be lower depending upon pump low pressure capability.
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3. Power Requirements
The TWLC torque wrench requires a hydraulic pump unit, twin-line connecting hose and couplings in
order to operate. All components must be capable of operating at the system maximum working pressure
of 690 Bar (10,000psi). Note that the system maximum working pressure is dynamic, not static.
Pump unit specification varies between manufacturers, however, in order for correct torque wrench
operation, the pump unit must include the following:
ouble Acting - Pump unit must be capable of double acting operation for advancing and retracting the
Torque wrench.
Variable Pressure Output - In order for torque setting, the pump unit must able to be easily adjusted by
the operator for different pressure outputs.
Retract Pressure - Sometimes termed ‘idle’ pressure, this is the pressure used for torque wrench
retraction and must be fixed at approximately 1000 psi (69 Bar). This pressure must not be Operator
adjustable.
Remote Handset Controls - The preferred configuration for the handset is such that upon starting the
pump unit, the pump enters retract or idle mode (pressure fixed at 69 bar). To advance the torque wrench,
the handset advance/pressure button or lever is pressed and held, upon release of the button, retract
mode is automatically entered. A separate button or lever is used to stop the pump.
Automatic Pressure Release - The pump must automatically release system pressure when switching
between advance and retract modes.
Pump Flow Rate - The speed at which the torque wrench operates is proportional to the oil flow rate. In
general, 2-stage pump units are preferred for torque wrench use as this allows rapid nut rotation under
low loads, with fast wrench retraction. As a minimum, 250 cm
3
/min @ 7 Bar to 20cm
3
/min @ 690 Bar
should be specified, however for optimum speed and performance we would recommend at least 360
cm
3
/min @ 7 Bar to 30 cm
3
/min @ 690 Bar.
Pressure Gauge - Clarity is important for accurate torque setting, therefore a pressure gauge of at least
100mm diameter should be fitted.
Hydraulic Couplings - LWLC torque wrenches are fitted with CEJN 230 screw-to-connect couplings (1/4”
NPT) as standard. Ensure that any couplings that are used are compatible with these couplings and rated
to the same working pressure, e.g. Parker 3000 couplings.
Many pump units are available which are suitable to operate the LWLC torque wrench, however, we
would strongly recommend that SPX Bolting Systems power packs are used, as they have been
rigorously tested both for compatibility and performance.
SPX Bolting Systems will not be responsible for torque wrench damage, malfunction or Operator injury
due to the use of an incorrect pump unit, therefore please check the compatibility of your pump unit prior
to torque wrench operation.
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4. Safet
Always adopt safe working practices when working with pressurized equipment. Protective clothing
including eye and head protection must always be worn as well as gloves and safety footwear. Exhibit
common sense and most importantly of all, REA AN UN ERSTAN THE OPERATING MANUAL AN
PROCE URES.
a) Never exceed the torque wrench maximum working pressure (Advance 689 Bar / 10,000 psi, Retract
69 Bar / 1000 psi)
b) Keep hands and fingers clear of the torque wrench head and reaction pad area, before and during
operation. Fingers could be inadvertently trapped if care is not taken.
c) Keep other personnel clear of the working area and only allow trained personnel to use the
equipment. Ideally rope off the working area.
d) Prior to operation, ensure that all hoses, sockets and ancillary equipment are undamaged and fit for
purpose. Ensure that all torque wrench components (i.e. head, body, etc.) are properly attached and
secure. Ensure that the head release pin is properly located.
e) o not strike any of the components, including the socket, with a hammer in order to shock the nut
free.
f) Check that reaction structures are strong and rigid enough to accept the torque tool reaction forces.
o not use wedges, packing pieces, etc as a temporary reaction.
g) If backing spanners are used, keep hands and limbs well clear of the backing spanner, as it may
rotate during wrench operation.
h) Take care when handling equipment. o not manoeuvre or carry the torque wrench by its couplings.
Quick connect couplings are especially susceptible to knocks and damage and therefore care must
be taken. Note that damaged couplings are difficult to connect. o not force couplings.
i) Check that hoses are in good condition and undamaged. When assembling the hydraulic hose, do
not unduly bend hoses beyond their safe bend radius limit or kink the hose.
j) o not retighten any equipment while under pressure. o not move or rotate the swivel manifold
while under pressure.
k) Ensure that any sockets or inserts that are to be used with the torque wrench are of impact quality
and capable of withstanding the full torque output of the tool.
l) Some torque wrenches weigh in excess of 20Kg, therefore ensure that lifting equipment is available
and used.
m) o not strike, misuse or abuse any of the equipment. If any abuse or misuse of the equipment is
evident, the warranty shall be invalid and the Manufacturer shall not be responsible for any injuries or
failures as a result.
n) In some instances it may be necessary for the Operator to support the torque wrench while it is
tightening, i.e. upside down applications. If the torque tool cannot be strapped into position using
ropes, etc, then the operator must take the utmost care to avoid pinch points.
o) Never use the torque wrench with just one hose connected to the Advance port (port ‘A’). This will
cause a pressure intensification within the retract chamber possibly leading to tool damage. Always
ensure that both hoses are connected.
p) If not in use, and when practical, disconnect the wrench and pump from the power supply to prevent
accidental starting.
THE LWLC TORQUE WRENCH IS ESIGNE FOR THE TORQUE TIGHTENING OF ENGINEERING
NUTS ONLY. O NOT USE IT FOR ANY OTHER PURPOSE
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5. Preparing the Torque Wrench for Use
Assembling / Removing the rive Head
Before the LWLC torque wrench can be used the correct drive head for the nut must be fitted to the LWLC
body. Note that no special tools or spanners are needed to change the drive head.
DISCONNECT FROM THE HYDRAULIC SUPPLY BEFORE ATTEMPTING TO CHANGE THE TORQUE
WRENCH HEAD. OPERATING THE WRENCH WITHOUT THE HEAD ATTACHED EXPOSES THE
MOVING PISTON DRIVE MECHANISM, AND COULD RESULT IN TRAPPED FINGERS OR OTHER
INJURY.
If a drive head is already assembled, it can be detached by pushing out the head retainer pin, and simply
lifting out the body. The drive assembly will auto-disengage.
NOTE : THE HEA RETAINER PIN IS HEL CAPTIVE WITHIN THE HEA SI EPLATE, IT CANNOT
BE COMPLETELY REMOVE
To assemble a drive head, position the drive head onto the body, engaging the keyways on the inner
surface of the drive head sideplates with the keys on the body. Slide the drive head fully onto the body
and push the head retaining pin back into position. See Fig. 2 below.
ENSURE THAT THE PIN IS FULLY ENGAGED, OTHERWISE DAMAGE TO THE BODY COULD
OCCUR IF OPERATED WITH A PART ENGAGED PIN. CONTINUALLY CHECK DURING OPERATION
THAT THE PIN IS FULLY ENGAGED AS MOVEMENTS OF THE WRENCH, AND HANDLING, CAN
CAUSE THE PIN TO DISLODGE.
Note that the body to head drive mechanism will auto engage during the drive head assembly process. If it
does not, it will automatically attach during the first power stroke of the torque wrench.
NOTE: The torque wrench must be fully retracted before the head can be removed or attached.
NOTE :
HEA RETAINING PIN OES
NOT ETACH FROM THE BO Y. IT IS
HEL CAPTIVE WITHIN THE SI EPLATE.
O NOT PUNCH OUT !!
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Fig 2. BODY AND DRIVE HEAD REMOVAL AND ATTACHMENT
Positioning the Torque Tool onto the Nut
The LWLC torque wrench locates directly around the nut, with it’s built-in reaction pad designed to react
against an adjacent nut. Fig. 3 below indicates correct positioning of the torque tool (shown in tightening
mode). Always ensure that the reaction pad butts firmly against an adjacent nut or secure reaction
structure.
Fig 3. CORRECT POSITIONING OF TORQUE WRENCH
Reaction Point Safety
Extreme care must be taken when selecting appropriate reaction points and the following must be borne
in mind at all times.
• The reaction structure must be rigid enough to accommodate the reaction forces from the torque
wrench, which can be extreme at times. Carefully assess the reaction points for suitability before
applying the torque tool. If in doubt, contact the torque wrench supplier for advice.
• Ensure that the reaction structure is suitably shaped to accommodate the reaction pad, Tapered
surfaces are generally unsuitable as the torque wrench tends to ‘ride up’ the taper, causing
adverse tool loads. Flat surfaces are most preferred.
• If in any doubt over the suitability of the reaction point, contact your torque wrench Supplier as
various reaction accessories are available which may prove more suitable.
• on’t improvise. Packing pieces, spacers, etc. are dangerous and must never be used as a
makeshift reaction point.
REACTION PA BUTTE
FIRMLY AGAINST AN
A JACENT NUT
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Use of Backing Spanners
Backing spanners are often used to prevent the non tightening nut on the opposite side of the joint
assembly from turning during the torquing operation. Ensure that the backing spanner is the correct size
and securely fastened in position (using straps, ropes, etc). As the torquing operation commences, it is
normal for the backing spanner to move / rotate in conjunction with the ‘torqued’ nut, until the backing
spanner abuts an adjacent reaction point. It is important that the operator stands clear of the moving
backing spanner to prevent accidental entrapment. The operator must also ensure that the reaction point
is secure and sufficiently rigid to prevent damage to the structure.
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