14
1 陕西恒瑞测控系统有限公司 HighReach Measuring & Controlling System Co., Ltd. Tel: +86-29-88338837 Fax: +86-29-88778890 Website: http://www.highreachtorquetools.com Operation Manual HTW Hydraulic Torque Wrench

Llaves de Torque Hidráulica

Embed Size (px)

Citation preview

Page 1: Llaves de Torque Hidráulica

1

陕 西 恒 瑞 测 控 系 统 有 限 公 司HighReach Measuring & Controlling System Co., Ltd.

Tel: +86-29-88338837

Fax: +86-29-88778890

Website: http://www.highreachtorquetools.com

Operation ManualHTW Hydraulic Torque Wrench

Page 2: Llaves de Torque Hidráulica

2

OPERATION AND MAINTENANCE MANUALThe maintenance manual includes the operation regulations, warning and attentions ofseries HTW-D and HTW-H of the hydraulic torque wrench. Read this maintenance manualcarefully before operating, fully understand it and take care to keep it. The maintenancemanual is only for end user’s reference.

1. Notice for receiving the goods (Open the box and inspect)Carefully check the received product to see if there is any damage or losses duringtransportation. Transportation damage or losses are out of our warranty. In case of anydamage or losses occurred during transportation, please immediately contact with theshipping company, they should pay for the repairing and replacing costs.

Safety the firstThe hydraulic torque wrench is a kind of dynamical tool. Before operating, please read allthe instructions, warning and attentions carefully. Obey the safe regulation to avoid anydamages may occur upon body or on equipment when operating! We will not beresponsible for those damages caused by insecurity operation and mistaking operation.

2. Products DescriptionSeries HTW-D and HTW-H hydraulic torque wrenches are made with aluminum-titaniumalloy and high strength alloy. They are designed as double-function hydraulic and can becontrolled by hand. It can be used for tightening or release the bolts connections, they arewidely-used for unloading large torque bolts. The torque value can be adjusted, and theerror is less than±3%.

The structure of HTW-D is shown in Fig.1:

Page 3: Llaves de Torque Hidráulica

3

The structure of HTW-H is shown in Fig.2:

Fig 2

3. WARNINGS:

Warning To avoid any damage may occur upon body and equipment, pleasemake sure each part of hydraulic components operating pressureunder 70MPa.

Warning Don't exceed rated load of equipment

Reduce the overload danger at any possibility. Use the manometer

display the operating load. The manometer is an indicating window

of the system pressure.

Warning Replacing the damaged parts by original parts made by factory as

soon as possible.

Attention Avoid any possible damage/injure on the hydraulic hoses

The hose bend and twist should be avoided during operation. It

could make a large pressure inside hose. Any big bending or

twisting will cause damages inside. Don't drop/put the heavy objects

on the hose. The serious impact could injure the inner metal of the

hose. The injured hose can be broken while pressing. Don’t pull and

hang hydraulic parts(Such as pump, hydraulic torque wrench and

valve etc.)by the hose.

No. Description

1 Ratchet link head

2 Reaction stopper

3 Hexagon Ratchet

4 Swivel assy 180*360

5 Cylinder head

6 Hinge pin

Page 4: Llaves de Torque Hidráulica

4

Warning To avoid any damages may occur upon body and equipment, please

don’t remove the shield of the wrench, don’t change the wrench

construction or any parts, Don’t change the safe valve on the

adapter.

Attention Incorrect connection may cause failure and dangerous. Please besure the adapter is clean before make the connection, and screw upthe dust proof cover after operation.

Attention Don’t use any damaged socket and plug;Don’t use meter socket totighten the inch nut and bolt . The reverse is the same.

Warning Tighten the socket head with bolt to avoid socket’s fall

4. Table 1 of recommending bolts torque value

Note:

class ofStrength

4.8 6.8 8.8 10.9 12.9

Min. breakStrength

392MPa 588 MPa 784 MPa 941 MPa 1176

Materials General steel Machinery steelAlloy steel

Chrome-molybdenumAlloy steel

nickel - Chrome-Alloy steel

nickel –Chrome-

molybdenumAlloy steel

b o l t n u t torque torque torque torque torqueM mm Kgm N.m Kgm N.m Kgm N.m Kgm N.m Kgm N.m14 22 7 69 10 98 14 137 17 165 23 22516 24 10 98 14 137 21 206 25 247 36 36318 27 14 137 21 206 29 284 35 341 49 48020 30 18 176 28 296 41 402 58 569 69 48022 32 23 225 34 333 55 539 78 765 93 91124 36 32 314 48 470 70 686 100 981 120 117627 41 45 441 65 637 105 1029 150 1472 180 176430 46 60 558 90 882 125 1225 200 1962 240 235233 50 75 735 115 1127 150 1470 210 2060 250 245036 55 100 980 150 1470 180 1764 250 2453 300 294039 60 120 1176 180 1764 220 2156 300 2943 370 362642 65 155 1519 240 2352 280 2744 390 3826 470 460645 70 180 1764 280 2744 320 3136 450 4415 550 539048 75 230 2254 350 3430 400 3920 570 5592 680 666452 80 280 2744 420 4116 480 4704 670 6573 850 833056 85 360 3528 530 5149 610 5978 860 8437 1050 1029060 90 410 4018 610 5978 790 7742 1100 10791 1350 1323064 95 510 4998 760 7448 900 882068 100 580 5684 870 8526 1100 1078072 105 660 6468 1000 9800 1290 1264276 110 750 7350 1100 10780 1500 1470180 115 830 8143 1250 12250 1850 1813085 120 900 8820 1400 13720 2250 2205090 130 1080 10584 1650 16170 2500 24500100 145 1400 13720 2050 20090110 155 1670 16366 2550 24990120 175 2030 19894 3050 29890

Page 5: Llaves de Torque Hidráulica

5

The data of the table is referred to the Germany industrial standard and tested on the 80%limit of the bolt strength. Suggest the tightening torque: The data in above tale ×80%(90%.For example: if boltM52. class8.8, the tightening torque is: 4704×90%=4233.6N.mThe releasing torque is 1.5 ~2 times of tightening torque.For example: if the tightening torque is 4233.6 N.m. then, the releasing torque is4233.6×1.5(2)=6350.4(8467.2)N.m

5. OPERATIONConnectionWrench and hydraulic pump are connected via a 70MPa steel wire hose. Each end of thehose has a male and female adapter to ensure the correct connection.Don’t revolve any bolt of the adapter randomly; this is designed for safety by the factory.Only professional can adjust it

Fig.3While connect the quick speed adapter, the gap of each other must be 0.5~1mm to insurethe single valve of the adapter opened to make the oil flow freely. Otherwise, afterconnecting, the steel ball inside the adapter is not tipped and the single valve could not beopened as a result of the oil flow isn’t free. In this condition the hose inside will be full ofpressure, it may cause the failure like the wrench doesn’t rotating and the oil leak out of theauto-leak out mouth of the wrench.

Fig.4If in this failure, it needs to remove all the adapters of the hose, check the steel ball insideall adapters by hand to find whether or not the ball is moveable and elastic. If the steel balldoesn’t move, you should knock the steel ball with the hammer (See in Fig.5).To release the pressure inside the adapter until you could press the steel ball move byhand, connect it again. While knocking the steel ball, the hydraulic oil can spray out,although this is not dangerous, it could make your clothes dirty.

Page 6: Llaves de Torque Hidráulica

6

Fig.5

Series HTW-DDrive direction changingPress the circle button on the drive retainer (Fig.6); pull the square drive slightly todisengage the connection of the drive shaft and locker, the square drive axes can be pullout.

Fig.6Put the square drive axes into the wrench, set the direction as Fig.7 and make a fullconnection with the spline, then rotating the square drive axes to fully match with thespline and ratchet , the ratchet drives the square drive axes rotating.

Fig 7

PreparationDetermine loosing or tightening the nut.Press the retainer on the square drive, take out the square drive axes and change thedirection at left and right as the Fig 7, Install the drive retainer. Pull down the reaction armlever; install the reaction arm at proper position when removing the retainer of the squaredrive sees in Fig.7.Pump station connectionConnect the pump and the hydraulic wrench with the high or low pressure outputsseparately. The high pressure exits (H or A) and the low pressure exits (L or R) of the pump

Page 7: Llaves de Torque Hidráulica

7

correspond with the hydraulic wrench .The quick-speed adapter of the hose should beinserted to the end, and then tighten the nut by hand.Check carefully to make sure the hose adapter is in reliable connection and oil is enoughinside the pump.Insert the power plug into the socket.Warning: Never running the pump without oil!

Test RunningPut the wrench on the ground.Switch on the pump. Check the pump operating normally.Press a button on the line-control switch, at this time the square drive starts turning. Whenyou hear a voice “Pa”, the recover trigger is jumped down, the wrench stops running at theposition. The manometer rises quickly from “0” to the setting position. Loose the button,the wrench returns to original position automatically. When you hear a voice “Pa” again,the wrench returns to original position automatically. The manometer rises quickly from “0”to 7.5MPa. Press the button again; at this time the wrench rotates, a new circle begins.Repeat it several times to make the wrench rotating well, Observe the wrench rotatingdirection to ensure it is in right running.Attention: When the wrench is not in use, please shut down the power supply of the pumpimmediately!

OPERATIONAdjusting pressurePress the control switch by one hand when you hear a voice “Pa”, the recover trigger isjumped down, the wrench stops running when at the right position. The manometer risesquickly from “0”, adjust the valve of the pump by the other hand, and adjust the pointer ofthe manometer to the required pressure.LoosingAdjust the pressure of pumping station to the max. Pressure value, be sure the wrench is inright loosing direction, put the wrench on the nut, look for the reaction pivot and lean on.Operate per the step in third section to remove the nut.Tightening1. Setting Torque valueSetting the torque value per the design needs. If no designing torque value, we recommendto use the bolts torque value as recommending in table 1. The calculating method is:Setting torque value=(data in the table 1) ×(80%~90%).For example: if the bolt is M48, class 8.8, the recommending torque in the table is 3920N.m,then set torque value is: 3920×90%=3528N.m.2. Setting pressure of the pumping stationAs the requirements of the value and the wrench model, then set pressure of the pumpingstation. As following example: if the bolt is M48, class 8.8, setting torque value 3528N.m,Torque wrench model HTW-D-3, then you can see the Item 6. of table 2 for Type HTW-D-3wrench, the pressure of the pumping station is 54MPa at the torque 3528N.m. So, pressureof the pumping station shall be set at 54MPa.3. Make sure the wrench direction is at the locking direction, put the wrench on the nut, andoperate per the step in third section until the nut doesn’t move.

Page 8: Llaves de Torque Hidráulica

8

When the wrench is locking and can’t be taken down during operation:During operation, after locking the bolt, when the wrench is locked and cannot be takendown, Never beat it by a hammer; you may keep pressing the line control switch (Button),not release it, synchronously, press down the quick speed lever (Fig.8) and keep it, thenrelease the button, at this time, the wrench will be loose automatically, take down thewrench, increasing the pump pressure, then tightening the bolts, and release it.

Fig 8Series HTW-H

Assembly and disassembly of the ratchet link head and cylinder head (Fig9&10)Disassembly:1. Connect the hydraulic torque wrench with the hydraulic pump;2. Operate the wrench, let the piston retract back to the end of the cylinder(Fig 10);3. Push the hinge pin from the wrench till the pin separate with the wrench entirely;4. As Fig 10, upward the cylinder head to finish the disassemble of hydraulic torquewrench.

Assembly:1. Let the piston retract back to the end of the cylinder;2. Turn the hexagon ratchet in clockwise direction to the end;3. Downward the cylinder head into the ratchet link head(the opposite direction todisassembly), make sure the hinge pin holes on the ratchet link head and cylinder head ingood alignment;4. Push the hinge pin into the hinge pin hole entirely, then finish the assembly.

Page 9: Llaves de Torque Hidráulica

9

Direction positionThe loosing and tightening steps of the hexagon cassette hydraulic torque wrench areloosing at left and tightening at right. In operation, the counterforce arm or right angle shallbe leaned at a reliable counterforce supporting point.

Fig. 11

PreparationCheck the removal (locking) nut size, choose a suitable drive head, working head andaccessories.Connection the pumping stationConnecting the high pressure exits (H or A) of the pump to the related high pressureoutputs (H or A) of the hydraulic wrench, connecting the low pressure exits (L or R) of thepump to the low pressure output (L or R) of the hydraulic wrench, make sure the quickspeed adapter of the hose should be inserted fully to the end, and then tighten the nut.Check and ensure all the connections are reliable, and enough oil inside the pump.Power plug is inserted into the socket.Warning: Never running without oil!

Test RunningPut the wrench on the ground.Switch on the pump, check the pump operating normally.Press a button on the line-control switch, at this time the ratchet wheel starts turning. Whenyou hear the voice “Pa”, the wrench stops running at the position. The manometer risesquickly from “0” to the setting position. Loose the button, the wrench returns to originalposition automatically. When you hear a voice “Pa” again, the wrench returns to the rightoriginal position automatically. The manometer rises quickly from “0” to 7.5MPa. Press thebutton again; at this time the wrench rotates, a new circle begins. Repeat it several times tomake the wrench rotating well, Observe the wrench rotating direction to ensure it is in rightrunning.Attention:When the wrench is not in use, please shut down the power supply immediately!

OPERATIONAdjusting pressurePress the control switch by one hand when you hear a voice “Pa”, the recover trigger is

Page 10: Llaves de Torque Hidráulica

10

jumped down, the wrench stops running when at the right position. The manometer risesquickly from “0”, adjust the valve of the pump by the other hand, and adjust the pointer ofthe manometer to the required pressure.LoosingAdjust the pressure of pumping station to the max. pressure value, be sure the wrench is inright loosing direction, put the wrench on the nut, look for the reaction pivot and lean on.Operate per the step in third section to remove the nut.Tightening1. Setting Torque valueSetting the torque value per the design needs. If no designing torque value, we recommendto use the bolts torque value as recommending in table 1. The calculating method is:Setting torque value=(data in the table 1) ×(80%~90%).For example: if the bolt is M48, class 8.8, the recommending torque in the table is 3920N.m,then set torque value is: 3920×90%=3528N.m.2. Setting pressure of the pumping stationAs the requirements of the value and the wrench model, then set pressure of the pumpingstation. As following example: if the bolt is M48, class 8.8, setting torque value 3528N.m,Torque wrench model HTW-H-4, then you can see the Item7. of table 3 for Type HTW-H-4wrench, the pressure of the pumping station is 47MPa at the torque 3528N.m. So, pressureof the pumping station shall be set at 47MPa.3. Make sure the wrench direction is at the locking direction, put the wrench on the nut, andoperate per the step in third section until the nut doesn’t move.

When the wrench is locking and can’t be taken down during operation:During operation, after locking the bolt, when the wrench is locked and cannot be takendown, Never beat it by a hammer; you may keep pressing the line control switch (Button),not release it, synchronously, press down the reaction stopper (Fig.12) and keep it, thenrelease the button, at this time, the wrench will be loose automatically, take down thewrench, increasing the pump pressure, then tightening the bolts, and release it.

Fig.126. Torque chart for HTW-D hydraulic torque wrench

Table 2

Type HTW-D-1 HTW-D-3 HTW-D-5 HTW-D-8 HTW-D-10 HTW-D-20 HTW-D-25 HTW-D-35MPa N.m N.m N.m N.m N.m N.m N.m N.m7 194 460 768 1100 1583 2721 3645 73208 222 526 878 1257 1810 3109 4165 80029 249 591 988 1414 2036 3498 4686 868410 277 657 1097 1572 2262 3887 5207 936611 305 723 1207 1729 2488 4276 5727 1004812 332 789 1317 1886 2714 4664 6248 10730

Page 11: Llaves de Torque Hidráulica

11

13 360 854 1427 2043 2941 5053 6769 1141214 388 920 1536 2200 3167 5442 7289 1209415 416 986 1646 2357 3393 5830 7810 1277616 443 1051 1756 2515 3619 6219 8331 1345817 471 1117 1866 2672 3845 6608 8851 1414018 499 1183 1975 2829 4072 6996 9372 1482119 526 1249 2085 2986 4298 7385 9892 1550320 554 1314 2195 3143 4524 7774 10413 1618521 582 1380 2305 3300 4750 8162 10934 1686722 609 1446 2414 3457 4976 8551 11454 1754923 637 1511 2524 3615 5203 8940 11975 1823124 665 1577 2634 3772 5429 9328 12496 1891325 693 1643 2744 3929 5655 9717 13016 1959526 720 1709 2853 4086 5881 10106 13537 2027727 748 1774 2963 4243 6107 10495 14058 2095928 776 1840 3073 4400 6334 10883 14578 2164129 803 1906 3183 4558 6560 11272 15099 2232330 831 1971 3292 4715 6786 11661 15620 2300531 859 2037 3402 4872 7012 12049 16140 2368732 886 2103 3512 5029 7238 12438 16661 2436933 914 2169 3622 5186 7465 12827 17182 2505134 942 2234 3731 5343 7691 13215 17702 2573335 970 2300 3841 5501 7917 13604 18223 2641536 997 2366 3951 5658 8143 13993 18744 2709737 1025 2431 4060 5815 8369 14381 19264 2777938 1053 2497 4170 5972 8596 14770 19785 2846139 1080 2563 4280 6129 8822 15159 20306 2914240 1108 2629 4390 6286 9048 15547 20826 2982441 1136 2694 4499 6443 9274 15936 21347 3050642 1163 2760 4609 6601 9500 16325 21868 3118843 1191 2826 4719 6758 9727 16713 22388 3187044 1219 2891 4829 6915 9953 17102 22909 3255245 1247 2957 4938 7072 10179 17491 23430 3323446 1274 3023 5048 7229 10405 17880 23950 3391647 1302 3089 5158 7386 10631 18268 24471 3459848 1330 3154 5268 7544 10858 18657 24992 3528049 1357 3220 5377 7701 11084 19046 25512 3596250 1385 3286 5487 7858 11310 19434 26033 3664451 1413 3351 5597 8015 11536 19823 26554 3732652 1440 3417 5707 8172 11762 20212 27074 3800853 1468 3483 5816 8329 11989 20600 27595 3869054 1496 3549 5926 8486 12215 20989 28115 3937255 1524 3614 6036 8644 12441 21378 28636 4005456 1551 3680 6146 8801 12667 21766 29157 4073657 1579 3746 6255 8958 12893 22155 29677 4141858 1607 3811 6365 9115 13120 22544 30198 4210059 1634 3877 6475 9272 13346 22932 30719 4278260 1662 3943 6585 9429 13572 23321 31239 4346361 1690 4009 6694 9587 13798 23710 31760 44145

Page 12: Llaves de Torque Hidráulica

12

62 1717 4074 6804 9744 14024 24099 32281 4482763 1745 4140 6914 9901 14251 24487 32801 4550964 1773 4206 7024 10058 14477 24876 33322 4619165 1801 4271 7133 10215 14703 25265 33843 4687366 1828 4337 7243 10372 14929 25653 34363 4755567 1856 4403 7353 10530 15155 26042 34884 4823768 1884 4469 7463 10687 15382 26431 35405 4891969 1911 4534 7572 10844 15608 26819 35925 4960170 1939 4600 7682 11001 15834 27208 36446 50283

7. Torque chart for HTW-H hydraulic torque wrenchTable 3

Type HTW-H-2 HTW-H -4 HTW-H -8 HTW-H -14 HTW-H -18 HTW-H-30MPa N.m N.m N.m N.m N.m N.m7 186 530 1020 1790 2400 41808 213 606 1166 2046 2743 47779 239 681 1311 2301 3086 537410 266 757 1457 2557 3429 597111 292 833 1603 2813 3771 656912 319 909 1749 3069 4114 716613 345 984 1894 3324 4457 776314 372 1060 2040 3580 4800 836015 399 1136 2186 3836 5143 895716 425 1211 2331 4091 5486 955417 452 1287 2477 4347 5829 1015118 478 1363 2623 4603 6171 1074919 505 1439 2769 4859 6514 1134620 531 1514 2914 5114 6857 1194321 558 1590 3060 5370 7200 1254022 585 1666 3206 5626 7543 1313723 611 1741 3351 5881 7886 1373424 638 1817 3497 6137 8229 1433125 664 1893 3643 6393 8571 1492926 691 1969 3789 6649 8914 1552627 717 2044 3934 6904 9257 1612328 744 2120 4080 7160 9600 1672029 771 2196 4226 7416 9943 1731730 797 2271 4371 7671 10286 1791431 824 2347 4517 7927 10629 1851132 850 2423 4663 8183 10971 1910933 877 2499 4809 8439 11314 1970634 903 2574 4954 8694 11657 2030335 930 2650 5100 8950 12000 2090036 957 2726 5246 9206 12343 2149737 983 2801 5391 9461 12686 2209438 1010 2877 5537 9717 13029 2269139 1036 2953 5683 9973 13371 2328940 1063 3029 5829 10229 13714 23886

Page 13: Llaves de Torque Hidráulica

13

41 1089 3104 5974 10484 14057 2448342 1116 3180 6120 10740 14400 2508043 1143 3256 6266 10996 14743 2567744 1169 3331 6411 11251 15086 2627445 1196 3407 6557 11507 15429 2687146 1222 3483 6703 11763 15771 2746947 1249 3559 6849 12019 16114 2806648 1275 3634 6994 12274 16457 2866349 1302 3710 7140 12530 16800 2926050 1329 3786 7286 12786 17143 2985751 1355 3861 7431 13041 17486 3045452 1382 3937 7577 13297 17829 3105153 1408 4013 7723 13553 18171 3164954 1435 4089 7869 13809 18514 3224655 1461 4164 8014 14064 18857 3284356 1488 4240 8160 14320 19200 3344057 1515 4316 8306 14576 19543 3403758 1541 4391 8451 14831 19886 3463459 1568 4467 8597 15087 20229 3523160 1594 4543 8743 15343 20571 3582961 1621 4619 8889 15599 20914 3642662 1647 4694 9034 15854 21257 3702363 1674 4770 9180 16110 21600 3762064 1701 4846 9326 16366 21943 3821765 1727 4921 9471 16621 22286 3881466 1754 4997 9617 16877 22629 3941167 1780 5073 9763 17133 22971 4000968 1807 5149 9909 17389 23314 4060669 1833 5224 10054 17644 23657 4120370 1860 5300 10200 17900 24000 41800

8. Failure and elimination

Failure Reason Solution

Piston doesn’t riseor compressed

Quick speed adapter doesn’tconnect well.

Check quick speed adapter.Make sure it is well connected

Quick speed adapter is in somefailure

Replace by a new one

Remote control is in some failure Replace by a new oneDirty enters into the direction

controller on the pumpDisassembly pump and clean the

valve

Page 14: Llaves de Torque Hidráulica

14

HIGHREACH MEASURING & CONTROLLING SYSTEM CO., LTD.

Building D, No.195, Gaoxin Avenue, Baoji, Shaanxi, China

BAOJI HEADQUARTERTel: +86-917-8695588 Fax: +86-917-3208995

XI’AN OFFICE

Tel: +86 29-88338837 Fax: +86 29-88778890E-mail: [email protected] Website: www.highreachtorquetools.com

Square drivedoesn’t rotate

There are some oil or dirtybetween the ratchet and pawl

Take apart the ratchet and cleanthe oil and dirty

Ratchet or pawl is old or injured Replacing the old or injured parts

Pump can’t set forpressure

Releasing valve is in failure Check, adjust or replace thereleasing valve

Power voltage is too low Make sure the current, voltage orother specifications are accordingwith the operation.

Manometer is in failure Replace by a new oneoil is not enough Check and add enough oilThe filter is blocked Check, clean or replace the filter

Bolts are runningwith backhaul

The ratchet is not match with thepawl.

Replacing the springs of theratchet or pawl