HTL DSX Series User manual

OPERATING INSTRUCTIONS

HTL-DSX

Dedicated Square Drive Wrench

Contents 2

Safety 2-3

Warranty 3

Connecting the tool 3-4

Setting the torque 4-5

Operating the wrench 5-6

Maintenance 6

Troubleshooting guide 6-7

Declaration 8

Notes 9-11

Spare parts 12-15

Please read this manual before operating the equipment.

Prior to commencement of bolt torqueing, ensure that:

• All necessary safety precautions have been carried out.

• Personnel involved in bolt torqueing are competent and fully trained in the use of torque

wrenches and tightening techniques.

• The procedure and data to be used is authorised by a responsible engineer.

• The joints / pipework to be worked on are not “live”. Joints must be at zero pressure and

free from hazardous substances.

• Bolt torqueing pressures, specific to the flanged joint to be tightened, are available.

Tips

• Always wear the appropriate safety equipment when operating this equipment; such as

safety goggles or safety glasses and protective gloves.

• Do not allow the hydraulic hose to kink, twist, curl or bend so tightly that the oil flow

within the hose is blocked or reduced. Never attempt to grasp a pressurised hose with

your hands.

• Use only a hydraulic pump capable of generating a maximum of 10,000 psi (700 Bar)

with this equipment.

• Never exceed the rated working pressure of the wrench.

• Do not place your hands between the wrench and the reaction point.

• Use the torque values specified by your equipment manufacturer whenever it is

available.

CONTENTS

SAFETY

Warnings

Any residual risks are identified within this manual with the equipment marked where

appropriate. Ensure these warnings are maintained.

The following label (s) are displayed on the machine for your safety, please observe all

warnings.

• You can be injured if you do not obey the safety instructions as

indicated on warning stickers.

• Observe all safety instructions and warnings attached to the machine

• Ensure that safety instructions and warnings attached to the machine

are always complete and perfectly legible.

• Keep warnings and instruction labels clean.

• Replace unreadable or missing labels with new ones before operating

the machine. Make sure replacement parts include warning or

instruction labels where necessary.

Hazard information signs

This warning indicates that there is a potential crush hazard and to keep

away from moving parts.

HTL Group Ltd guarantees its products against all design and manufacturing defects for 1 year

from the date of shipment. The guarantee does not include the ordinary wear of both metal and

non-metal parts, abuse, using the equipment beyond its rated capacity and any wear or damage

incurred as a result of using a hydraulic fluid which is not recommended by HTL Group Ltd.

Please note that if the equipment is disassembled or serviced by anyone other than an

authorised service dealer or by HTL Group Ltd, this guarantee is rendered null and void.

In the event of a warranty claim, return the equipment to HTL Group Ltd or the authorised dealer

which sold you the hydraulic equipment. HTL Group Ltd will repair or replace the faulty

equipment, whichever is deemed most appropriate.

The torque wrench and hydraulic pump are connected by a 10,000 PSI (700 Bar) twin-line hose

assembly. The safety ratio of the hydraulic hose is 4:1. On each twin hydraulic hose, one line

must be MALE-MALE and the other line must be FEMALE-FEMALE in order to ensure a correct

interconnection between the pump and wrench. Ensure the connectors are fully engaged and

screwed snugly together.

NEVER use two twin hydraulic hoses between the pump and wrench. If so, you have the high

pressure on the retract side and your wrench is not able to work properly. To avoid tool

WARRANTY

CONNECTING THE TOOL

malfunction, do not reverse connectors. Do not try to loosen the swivel assembly at any

moment.

Connect the twin-line hose to the swivel as shown:

Drive direction change

To remove the square drive, disengage the drive retainer assembly by depressing the round

center button and gently pulling on the square end of the square drive. The square drive will

easily slide out.

To insert the drive in the tool, place the drive in the desired direction, engage drive and bushing

splines, then twist drive and bushing until ratchet spline can be engaged. Push drive through

ratchet. Depress drive retainer button, engage retainer with drive and release button to lock.

The following diagram illustrates the direction the square drive should face for loosening and

tightening of a standard right hand fastener:

Reaction arm

The reaction arms are employed to absorb and counteract forces created as the unit operates,

which should extend in the same direction of the square drive; however, slight adjustments may

be made to suit your particular application.

In operation, the reaction arm must be fully engaged and secured. To engage the reaction arm,

depress the spring loaded button located on the rear of the end cap, push to position and

release to lock. Ensure the retainer is locked in place prior to using the wrench.

To remove the reaction arm, depress the spring loaded button located on the rear of the end cap

and pull to release.

After determining the desired torque, use the calibration certificate supplied with your wrench to

determine the pressure that is necessary to achieve that torque.

1. Connect the tool to the power supply and turn the pump on.

SETTING THE TORQUE

Right is

tight.

Left is

loose.

2. Depress the advance remote control button, causing the pressure to be shown on the

gauge.

3. Adjust the pressure by loosening the locking ring on the T Handle. Rotate the handle

clockwise to increase the pressure and counter clockwise to decrease the pressure.

When decreasing pressure, always lower the pressure below the desired point and then

bring the gauge back up to the desired pressure.

4. When the desired pressure is reached, retighten the locking ring, cycle the tool again to

confirm that the desired pressure setting has been obtained.

Tightening process

1. Having set your target pressure, cycle the wrench three or four times to full pressure

before putting it on the application. Cycling the tool ensures the system is operating

properly and removes trapped air, if any.

2. Place the correct size impact socket on the square drive and secure properly with a ring

and pin.

3. Place the tool and the socket on the nut, making sure that the socket has fully engaged

the nut. Further ensure that the drive retainer is engaged.

4. Make sure the reaction arm is firmly abutted against a stationary object (e.g. an adjacent

nut, flange, equipment housing etc.). When positioning the wrench, make sure that the

hose connections are well clear of any obstructions, and that all body parts are safely

out of harms way.

5. Apply momentary pressure to the system to ensure proper tool placement. If it doesn’t

look or act right, stop and readjust the reaction arm.

In use

1. By pushing down on the remote control button in the advance position, the rear of the

tool will be pushed back until the reaction arm makes contact with its reaction point.

2. Continue to hold down the button as the socket turns until the tool is fully extended and

will not turn the socket further. Successive cycles are made until the wrench stalls at the

preset torque.

3. The wrench will automatically reset itself and the operator will hear a series of clicks,

when the clicks finish the operator can again push the remote control button and the

socket will turn.

4. Continuing to hold down the remote control button will result in rapid build up of pressure

to the point of where the gauge reads what was preset prior to applying the wrench.

NOTE: The reading of full preset pressure after the cylinder is extended does not indicate that

this pressure (torque) is applied to the bolt. It only indicates that the cylinder is fully extended

and cannot turn the socket further until the wrench automatically resets itself.

OPERATING THE WRENCH

5. Always attempt one final cycle to ensure the stall point has been reached.

Loosening procedure

First, set the pump to 10,000 psi. Change the drive and the reaction arm to the loosening mode,

ensuring the reaction arm abuts squarely off a solid reaction point. Press and hold the pump

advance button down. Pressure will decrease as the socket beings to turn. As the cylinder

extends fully, you will hear a click. Release the remote control button, and the cylinder

automatically retracts, at which time you again hear the click. Repeat this process until the

fastener can be removed by hand.

NOTE: If the bolt / nut does not loosen with the above procedure, it is an indication that you

require the next larger size DSX to loosen the bolt.

Lubrication frequency depends on factors known only to the user. The amount of contaminants

in the working area is one factor. Wrenches used in a clean room environment will obviously

require less maintenance than wrenches used outdoors and dropped in loose dirt or sand.

1. When lubrication is required, lubricate all moving parts.

2. Springs are used for the drive pawl assembly and for the accuracy assurance pawl.

These springs can be replaced if necessary.

3. If the cylinder requires disassembly, it is recommended that the cylinder seals be

replaced at the same time. Seal kits are readily available.

4. Hoses should be checked for cracks and leaks before, and after each job. Hydraulic

fittings can become plugged with dirt and should be flushed periodically.

5. Fittings should be kept clean and not allowed to be dragged along the ground or floor as

even small particles of dirt can cause the internal valves to malfunction.

All structural parts on the tools should be inspected at least once a year to determine if there are

any cracks, chips, or deformities.

We recommend you use HTL Group’s Pro-Moly Lubricant

SYMPTOM PROBABLE CAUSE SOLUTION

Wrench

pressure will

not build

Piston seal and/or end plug

seal leaking Replace any defective o-rings.

Coupler is defective Replace any defective couplers.

Cylinder / Tool

Leaks

Blown o-ring in cylinder Replace seal kit.

Defective piston rod seal Return to HTL for repair.

TROUBLESHOOTING GUIDE

MAINTENANCE

Ratchet

returns with

retract stroke

Broken or otherwise inoperable

drive segment

Replace drive segment and/or spring. Return

to HTL.

Ratchet will

not take

successive

strokes

Broken or otherwise inoperative

drive segment or spring

Replace drive segment and/or spring. Return

to HTL.

Cylinder not retracting

completely

Remove tool from nut and cycle freely for

several strokes.

Allow adequate time for cylinder to retract

fully.

If problem persists, check pawls.

Linkage between piston rod and

drive plate is broken Replace parts as necessary - return to HTL.

Cylinder will

not retract

Voltage to electric pump is too

low to line drop or inadequate

amperage is available

Get shorter extension cord. If shop power is

adequate, draw power from welding machine

or cal. rod transformer.

Linkage between piston rod and

drive arms are broken Replace part as necessary

Tool locks on

to nut

Drive segment is loaded when

the tool is maxed out in torque

Pressure advance on remote and build

pressure - continue to press down on remote

while pulling back on one of the accuracy

assurance levers - release remote while

continuing to hold back on levers.

Tool is operating backwards Push advance button down - tool should

immediately fall free.

Tool is wedged under a fixed

object

Remove shroud from around ratchet. Pry the

drive segment out of the ratchet and at the

same time pull back on the accuracy

assurance levers. Tool should swing free or

burn away the socket or obstruction.

Tool operates

backwards Multiple hoses in even numbers Configure hoses in odd multiples only.

Pump will not

build up

pressure

Defective relief valve Inspect, adjust or replace the relief valve.

Air supply too low or air hose

too small

Make certain the air supply and hose size

comply with the pump manual

recommendations.

Electric power source is too low

Make certain the amperage, voltage and any

extension cord size comply with the pump

manual requirements.

Defective gauge Replace the gauge.

Low oil level Check and fill the pump reservoir.

Clogged filter Inspect, clean and/or replace the pump filter.

Tool operates

backwards Couplings reversed Check couplings and correct.

DECLARATION

NOTES

This manual suits for next models

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