Software Version BMDC 2.03 / BUIC 2.05 3rd. Edition Mar. 2017
This manual applies to all tool part numbers in the Lithium Product Family. It is
recommended that the manual is kept up-to-date by checking the edion and date code
at the boom of this page. The most recent edion can always be found on the Torque
Gun Company website.
LITHIUM GUN PRODUCT FAMILY:
EN, EN-ISO, ISO Standards:
BTM-0250, BTM-0700, BTM-1000,
BTM-2000, BTM-3000
TORQUE GUN
A HYTORC COMPANY
120 Wesley Street
Hackensack, NJ 07606
U.S.A.
Noce: The informaon contained in this document is subject to change without noce. The Torque
Gun Company makes no warranty of any kind with regard to this material, including but not limited
to, the implied warranes of merchantability and tness for a parcular purpose. The Torque Gun
Company shall not be liable for errors contained herein or for incidental or consequenal damages in
connecon with the furnishing, performance, or use of this material. It is further recommended that the
end-user or repair technician insure they have obtained and are familiar with the latest revision of the
manual for the equipment outlined in this document.
5002282
EN ISO 12100-1:2011
EN ISO 12100-2:2011
EN ISO 14121-1:2007
EN ISO 11148-6:2012
For a complete EC declaraon of conformity
or if you require any further assistance please
contact your local Torque Gun representave
or call 1-888-GUN-2-GUN (1-888-486-2486) or
use our website at www.torquegun.com.
Conforms to UL STDS 60745-1 & 60745-2-2
Certied to CSA STD C22.2 Nos. 60745-1 & 60745-2-2
For Hand-Held Motor-Operated Electric Tools.
Restricted Rights Legend: Use and duplicaon of the informaon contained within this manual is
limited to the purchaser, end user, or licensed Torque Gun Company representave. It is recommended
that proper training for the equipment outlined in this manual be conducted by a Torque Gun Company
authorized training representave for any person who is operang or repairing the equipment outlined
in this document. Modicaon of, or disclosure by any other agency or representave is strictly
forbidden.
Product Modicaons: The Torque Gun Company DOES NOT ALLOW any of the products listed in this
manual to be modied by any end user without excepon. Should an applicaon require a modicaon
to the tool, or any of the standard accessories please consult with your local Torque Gun Company
representave and they will be able to obtain the assistance for any modicaon that may be required.
Copyright © 2016 The Torque Gun Company All Rights Reserved. Reproducon, adaptaon, or
translaon without prior wrien permission is prohibited, except as allowed under the copyright laws.
3rd. Edion. Printed in USA. JUN. 2016
Complies with Standards Publicaon BS EN 82079-1:2012
WITH THE PURCHASE OF TORQUE GUN CO. TORQUE MACHINES (PAST,
PRESENT, FUTURE) YOU HAVE OBTAINED THE LATEST TECHNOLOGY AND
LIFETIME, WORLDWIDE LOCAL SERVICE.
FREE SERVICES
♦ FREE User Safety Training upon Receipt of Merchandise
♦ FREE Semi-Annual User Safety Training on Request
♦ FREE Annual Safety Seminar on Appointment
♦ FREE Loaner Tools in case of Product Failure within 24 Hours
♦ FREE Torque/Tension Consultation/Seminar
♦ FREE Half Day, First Use Supervision
♦ FREE Annual Product Inspection on Request
♦ FREE Product Demonstrations
♦ FREE 12 Month No-Questions-Asked Warranty
♦ FREE Upgrades during the Lifetime of the Tool to Enhance Safety, Durability, and Function
(Above services are NOT subject to travel expense charges)
REPAIRS
• All Repairs are Guaranteed for 6 Months
• Repairs are Subject to Labor and Part Cost, as Outlined in the Ofcial TORQUE GUN CO. Price List
• All Warranty Repairs are FREE of All Charges Including Return-Freight
• All Repairs Will be Tested and Calibrated to Ensure the Highest Quality Repairs
TOOL RENTALS
• 100% of all Paid Rentals Will be Applied as a Discount Towards any New Purchase in that Calendar Year.
• User Training for First Time Rentals is FREE of All Cost
• Return Freight Charges are FREE
• Rental Tools are Guaranteed to Perform and are Subject to the FREE Loaner Tool Policy of TORQUE GUN CO.
FIND US ONLINE AT
facebook.com/torcgun twitter.com/torcgun youtube.com/torqueguncompany
TOTAL SATISFACTION GUARANTEED 1-888-GUN-2-GUN
HELP: If you require any further assistance, please call your local Torque Gun Co. Representa-
tive or 1-888-GUN-2-GUN (1-888-486-2486 ), on the web at torcgun.com - 24/7! It’s live!
LITHIUM GUN™
OPERATIONS MANUAL
CONTENTS
Warranty 7
IMPORTANT SAFETY INFORMATION
Personal Protective Equipment
Lithium Ion Battery Care
Battery Gun Safety Warnings
Reaction Arm or HYTORC Washer
Reaction Assembly and Drive
Basic Safety Instructions for Handling
Important Battery Pack Safety Instructions
The RBRC Seal
OPERATION
General
Setup
Two Speed Operation
Battery Pack Installation and Removal
Charging Procedure
Power
Reaction Arm
Basic Operation
Setting Torque and Angle
Basic Function Description
8
8
9
11
12
15
16
17
19
20
20
20
21
21
21
22
22
23
TORQUE GUN OPERATION
Tightening
Loosening
Options
HYTORC Washer Overview
HYTORC Washer Requirements
HYTORC Washer Assembly Use and Service (SETUP)
Important Preparation Steps for the HYTORC Washer
Important Installation Steps for the HYTORC Washer
Installing HYTORC Washer Drive
Tightening with HYTORC Washer
MAINTENANCE
Preventive Maintenance
Calibration
APPENDIX
LITHIUM Gun Block Diagram
LITHIUM Gun Dimensions
LITHIUM Gun Top Level Assembly Print BTM-XXXX
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
4
23
24
24
29
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30
30
31
32
33
33
35
36
37
TABLE OF CONTENTS CONT’D
FIGURES
Figure 1: Lithium Gun
Figure 2: Reaction Arm
Figure 3: HYTORC Washer and Drive
Figure 4: Reaction Arm Assembly
Figure 5: Reaction Arm Attachment
Figure 6: Reaction Arm Fastening
Figure 7: Socket Drive
Figure 8: Socket Drive Attachment
Figure 9: Reaction Arm Positioning
Figure 10: LITHIUM Gun Overview
Figure 11: Gear Switch Detail
Figure 12: Charger Power Supply to Battery Cradle Connection
Figure 13: Main Screen Display
Figure 14: Setting Torque and Angle
Figure 15: HYTORC Washer and Driver
Figure 16: HYTORC Washer Installed
Figure 17: Installing Set Screw on HYTORC Washer Driver
Figure 18: Tighten Set Screw
Figure 19: HYTORC Washer Driver on LITHIUM
Figure 20: Lithium Gun Block Diagram
Figure 21: Lithium Gun Dimension
8
11
11
12
13
13
14
14
15
19
20
21
22
23
29
30
31
31
32
35
36
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
5
WARRANTY
The Lithium Torque Gun has a one year limited warranty. Every TORQUE GUN tool is tested before leaving the factory and is warranted to be free from defects in workmanship and materials. TORQUE GUN
will repair or replace, without charge, any tool which, upon examination, proves to be defective in workmanship or materials for one (1) year after the date of purchase. This warranty does not cover damage
resulting from repairs made or attempted by non-TORQUE GUN authorized repair facilities.
The repair and replacement remedies described herein are exclusive. In no event shall TORQUE GUN be
liable for any incidental, special, or consequential damages, including loss of prots.
This warranty is exclusive and in lieu of all other warranties or conditions, written or oral, expressed or
implied for merchantability or tness for particular use or purpose.
This warranty gives you specic legal rights. You may also have other rights that vary from state to state
and province to province. In those states that do not allow the exclusion of implied warranties or limitation of incidental or consequential damages, the above limitations or exclusions may not apply to you.
If you have questions about the warranty, contact our customer service center at
201-828-5270.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
6
IMPORTANT SAFETY INFORMATION
Read and understand this material before operating or servicing this equipment. Failure to understand
how to safely operate this tool could result in an accident causing serious injury or death.
• Inspect all lithium components as they are removed from the shipping container. If damage is
found to any component, contact the shipper immediately. Do not use the tool.
• Failure to follow correct tool usage could result in personal injury, co-worker injury, and/or
damaged tools and equipment.
• Ensure your working area is clean and unobstructed before beginning work.
• Lithium maintenance and repair must be performed by a qualied technician.
• Modifying a lithium or lithium accessory is dangerous and invalidates the warranty.
• Inspect the tool before each use. Have any obviously worn or damaged parts replaced.
• When not in use, store the LITHIUM and LITHIUM accessories in the plastic storage case
supplied with the tool. Do not expose the gun to high humidity or large temperature variations.
Personal Protective Equipment
• Always wear the appropriate personal protective equipment when operating a LITHIUM
including gloves, safety goggles, hearing protection, hard hat, and safety shoes.
Figure 1 - Lithium Gun
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
7
Lithium Ion Battery Care
Read and understand this material before operating or servicing this equipment. Failure to understand
how to safely operate this tool could result in an accident causing serious injury or death.
• Never disassemble, crush, or puncture a battery.
• Never short the external contacts on a battery.
• Never dispose of a battery in re or water.
• Never expose a battery to temperatures above 60 °C (140 °F).
• Never drop or impact the battery in any way.
• Never expose the battery to excessive shock or vibration.
• Never use a damaged battery
Battery Gun Safety Warnings:
WARNING Read all safety warnings and all instruction. Failure to follow the warnings and
instructions may result in electric shock, re, and/or serious injury
Save all warnings and instructions for future reference
1) Work Safety Area
• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• Do not operate the Battery Gun in explosive atmospheres, such as in the presence of
flammable liquids, gases or dusts. The Battery Gun can create sparks which may ignite the
dusts or fumes.
• Keep children and bystanders away while operating the Battery Gun. Distractions can
cause you to lose control.
2) Personal Safety
• Stay alert, watch what you are doing and use common sense when operating the
Battery Gun. Do not use the Battery Gun while you are tired or under the influence
of drugs, alcohol, or medication. A moment of inattention while operating the Battery Gun
may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective equipment
such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
• Prevent unintentional starting. Ensure the switch is in the off-position before
connecting to power source and or battery pack, picking up or carrying the tool.
Carrying the Battery Gun with your nger on the switch or energizing power tools that have the
switch on invites accidents.
• Remove any adjusting key or wrench before turning the Battery Gun on. A wrench or
a key left attached to a rotating part of the Battery Gun may result in personal injury.
• Do not overreach. Keep proper footing and balance at all times. This enables better
control of the Battery Gun in unexpected situations.
• Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and
gloves away from the moving parts. Loose clothes, jewelry or long hair can be caught in
moving parts.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
8
• If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of dust collection can
reduce dust-related hazards.
3) Battery Gun use and care
• Do not force the Battery Gun. Use the correct Battery Gun for your application. The
correct Battery Gun will do the job better and safe rat the rate for which it is designed
• Do not use the Battery Gun if the switch does not turn it on and off. Any Battery Gun
that cannot be controlled with the switch is dangerous and must be repaired
• Disconnect the plug from the power source and/or the battery pack from the
Battery Gun before making any adjustments, changing accessories, or storing
Battery Gun. Such preventive safety measures reduce the risk of starting the Battery Gun
accidentally.
• Store idle Battery Guns out of the reach of children and do not allow persons
unfamiliar with the Battery Gun or these instructions to operate the Battery Gun.
Battery Guns are dangerous in the hands of untrained users.
• Maintain Battery Guns. Check the misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power of tool’s
operation. If damaged, have the Battery Gun repaired before use. Many accidents are
caused by poorly maintained Battery Gun.
• Use the Battery Gun, accessories in accordance with these instructions, taking into
account the working conditions and the work to be performed. Using the Battery Gun
for the operations different from those intended could result in a hazardous situation.
4) Battery Gun use and care
• Rechargeable only with the charger specified by manufacturer. A charger that is
suitable for one type of battery pack may create as risk of re when used with another
battery pack.
• Use the Battery Gun only with specifically designated battery packs. Use of any other
battery pack my risk injury and re.
• When the battery pack is not in use, keep it away from other metal objects, like
paper clips, coins, keys, nails, screws and other small metal objects that can make
a connection from one terminal to another. Shorting the battery terminals together may
cause burns or a re.
• Under abusive conditions, liquid may be ejected from the battery; avoid contact. if
contact accidentally occurs, flush it with water. If liquid contacts eyes, additionally
seek medical help. Liquid ejected from the battery may cause irritation or burns.
5) Service
• Have your Battery Gun serviced by a qualified repair person using identical
replacement parts. This will ensure that the safety of the Battery Gun is maintained.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
9
Reaction Arm or HYTORC Washer
Use the appropriately sized reaction arm or HYTORC Washer based on your application. The LITHIUM is
usually supplied with a reaction arm in standard length. However, a custom reaction arm may have been
delivered for your special application.
Figure 2 - Reaction Arm
Figure 3 - HYTORC Washer and Driver
WARNING!
Never modify a Reaction Arm! Changes in the reaction arm may lead to personal injury or damage to the tool.
NOTE:
Reaction modications result in loss of warranty for the reaction arm and the
LITHIUM Gun. If you need a custom reaction arm, please consult with your
local TORQUE GUN dealer.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
10
Reaction Assembly and Drive
• If using the HYTORC Washer system, please follow the installation and assembly instructions in
the “Overview HYTORC Washer” section.
• Please clean the splined surface of the LITHIUM before mounting the reaction arm.
• Slide the reaction arm on the appropriate gear so that the extension of the reaction arm is
facing outward.
Figure 4 - Reaction Arm Assembly
WARNING!
Always attach the reaction arm so that the foot points away from the body of
the gun. Incorrect installation of the reaction arm can cause the reaction arm to
come into contact with your hand or other body parts causing injury.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
11
Figure 5 - Reaction Arm Attachment
Attach the Reaction to the LITHIUM so that the attachment screw with the recess corresponds to the
teeth, tighten and then loosen it a 1/4th turn.
Figure 6 - Reaction Arm Fastening
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
12
Figure 7 - Socket Drive
Secure the socket by means of locking pin on the square.
Figure 8 - Socket Drive Attachment
Store the reaction arm and LITHIUM gun in the tool box supplied after use and during work breaks.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
13
Basic Safety Instructions for Handling
Make sure the reaction arm sits directly in contact with a suitable immovable object before you start to
tighten the nut.
Figure 9 - Reaction Arm Positioning
The use of the HYTORC Washer makes the use of external reaction arms unnecessary and thereby
contributes to an increase in the safety of the user. (See section “Overview HYTORC Washer”)
• Keep all body parts from the reaction point.
• Make sure the operator is safe and secure in place before starting.
• Make sure the square drive is seated correctly and completely onto the socket.
WARNING!
If the reaction arm is not in direct contact with an immovable object before you
start the fastening process. It could cause you to lose control of the tool and
get injured. Make sure that any part of your body is never in the path of the
reaction arm, (the immovable object in contact with the reaction arm) when the
nut is tightened, otherwise serious injury may occur.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
14
IMPORTANT BATTERY PACK
INSTRUCTIONS
• DO NOT splash or immerse in water or other liquids.
• Do not incinerate the battery pack even if it is severely damaged or is completely worn out.
The battery pack can explode in a re. Toxic fumes and materials are created when lithium ion
battery packs are burned.
• Do not charge or use the battery in explosive atmospheres, such as in the presence of
flammable liquids, gases or dust. Inserting or removing the battery from the charger may ignite
dust or fumes.
• If battery contents come into contact with the skin, immediately wash area with mild soap
and water.
• If battery liquid gets into the eyes, rinse over the open eye for 15 minutes or until irritation
ceases. If medical attention is needed, the battery electrolyte is composed of a mixture of
liquid organic carbonates and lithium salts.
• Contents of opened battery cells may cause respiratory irritation. Provide fresh air. If
symptoms persist, seek medical attention.
WARNING: Burn hazard. Battery liquid may be ammable if exposed to spark or ame.
• Charge the battery packs only in battery chargers supplied for charging this product.
• DO NOT pack with conductive items.
WARNING: Never attempt to open the battery pack for any reason. If battery pack
case is cracked or damaged, do not insert into charger or tool. Do not crush, drop, or
damage battery pack. Do not use a battery pack or charger that has received a sharp
blow, has been dropped or has been run over or damaged in any way (i.e. pierced with
a nail, hit with a hammer, stepped on). Damaged battery packs should be returned to an
authorized HYTORC service center for recycling.
WARNING: Fire hazard. Do not store or carry battery so that metal objects can
contact exposed battery terminals. For example, do not place battery in aprons,
pockets, tool boxes, product kit boxes, drawers with loose nails, screws, keys etc.
Transporting batteries can possibly cause fires if the battery terminals inadvertently
come in contact with conductive materials such as keys, coins, hand tools and the
like.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
15
The US Department of Transportation Hazardous Materials Regulations (HMR)
actually prohibit transporting batteries in commerce or on airplanes, (i.e. packed
in suitcases and carry-on luggage). When transporting individual batteries, make
sure that the battery terminals are protected and well insulated from materials that
could contact them and cause a short circuit. For any other concerns in regarding the
transportation of LI-ION batteries, consult your Transportation Carrier.
TM
THE RBRC
The RBRCTM (Rechargeable Battery Recycling Corporation) Seal on the lithium ion battery (or battery
pack) indicates that the costs to recycle the battery (or battery pack) at the end of its useful life have
already been paid by HYTORC.
The RBRC
United States to facilitate the collection of spent lithium ion batteries. Help protect our environment and
conserve natural resources by returning the spent lithium ion battery to an authorized HYTORC service
center for recycling. You may also contact your local recycling center for information on where to drop
off the spent battery. RBRCTM is a registered trademark of the Rechargeable Battery Recycling Corporation.
TM
in cooperation with HYTORC and other battery users, has established programs in the
SEAL
IMPORTANT BATTERY CHARGER SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions for battery chargers:
• Before using charger, read all instructions and cautionary markings on charger, battery pack and
product using battery pack.
WARNING: Shock hazard. Do not allow any liquid to get inside charger.
CAUTION: Burn Hazard. To reduce the risk of injury, charge only Torque Gun batteries.
Other types of batteries may burst causing personal injury and damage.
CAUTION: Under certain conditions, with the charger plugged into the power supply, the
charger can be shorted by foreign material. Foreign materials of a conductive nature such
as, but not limited to, steel wool, aluminium foil, or any buildup of metallic particles should
be kept away from charger cavities. Always unplug the charger from the power supply
when there is no battery pack in the cavity. Unplug charger before attempting to clean.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
16
• DO NOT attempt to charge the battery pack with any chargers other than the one in this
manual. The charger and battery pack are specically designed to work together.
• These chargers are not intended for any uses other than batteries supplied with Lithium
series guns as described in this manual. Any other uses may result in risk of re, electric shock
or electrocution.
• Do not expose charger to rain or snow.
• To disconnect charger, firmly grasp plug and remove. Do not disconnect the charger by pulling on the cord.
• Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise
subjected to damage or stress.
• Do not use an extension cord unless it is absolutely necessary.
• An extension cord must have adequate wire size (AWG) for safety. In general the larger the
wire size the greater the capacity of the cable.
• Do not block any ventilation slots on charger power supply.
• Do not mount charger on wall or permanently fix charger to any surface. The charger is in-
tended to be used on a at surface (i.e. table top, bench top).
• Do not operate charger with damaged cord or plug. Have any damaged plug or cord replaced
immediately.
• Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged
in any way.
• Do not disassemble charger; take it to an authorized Torque Gun service center when service or repair is required.
• This charger is designed to operate on standard household electrical power (120V/220V
60hz/50hz).
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
17
OPERATION
General
Each Lithium Torque Gun is supplied completely assembled and ready for use. A full kit contains:
• Lithium Torque Gun
• Two 36V Li-ion 3.9Ah Battery Packs
• 36V Battery Charger
• Battery Charger Power Supply
• Reaction Arm
Figure 10 - LITHIUM Gun Overview
STATUS
LED
REACTION
ARM
MAIN
DISPLAY
GEAR
BOX
VENTS
BEARING
HOUSING
TRIGGER
SWITCH
36V
BATTERY PACK
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
18
SETUP
Two Speed Operation
Each Lithium Torque Gun is equipped with a two speed gearbox. The gearbox has two modes:
• RUNDOWN MODE: Used to run nuts down to seated position ready to torque.
• TORQUE MODE: Used for nal torqueing in TORQUE ONLY and TORQUE AND ANGLE
sub-modes.
To switch between RUNDOWN and TORQUE settings, ip the gear select switch located underneath the
front aluminium bearing housing. In the rare event the gear selector doesn’t engage, a very brief pulse
from the trigger is all that is needed to allow gear engagement.
Figure 11 - Gear Switch Detail
BATTERY PACK
RELEASE BUTTON
Battery Pack Installation and Removal
To install the battery pack into the tool handle, align the base of the battery with the rails in the tool handle and slide the battery pack rmly into the handle until you hear the lock snap in to place.
To remove the battery pack from the tool, press the release button (as shown above) and rmly slide the
battery pack out of the tool handle.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
19
Charging Procedure
1. Plug the charger power supply into the charger cradle using the three pin plug, then tighten the
retaining collar on the plug.
2. Plug the charger power supply into an appropriate outlet before inserting a battery pack.
3. Insert the battery pack into the charger cradle. The charger is equipped with a two light charge
indicator that will be either red or green according to the charged level of the battery pack.
4. The completion of the charge is indicated by a green light which also indicates an idle state. The
pack is fully charged and may be used at this time or left on the charger.
LED Indicators:
• No Battery Solid Green Light
• Charging Solid Red Light
• Fully Charged Solid Green Light
• Short Circuit Flashing Red Light
• Reverse Polarity Flashing Red Light
• Damaged Battery Flashing Red Light
Figure 12 - Charger Power Supply to Battery Cradle Connection
Power
The LITHIUM gun battery charger can operate at 110V or 220V AC. The plug is congured for North
American outlets, so other regions may require adapters.
Reaction Arm
Each LITHIUM gun is equipped with a universal reaction arm. The reaction arm is used to absorb and
counteract any opposing forces created by the operation of the torque gun. Use the appropriately sized
reaction arm or HYTORC Washer based on your application.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
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Basic Operation
Press any button to start the gun. The gun will shut itself off after 3 minutes of inactivity. See Figure 13
for the LITHIUM Torque Gun’s Main Screen Display. All gun parameters will be saved from the most
recent session.
Figure 13 - Main Screen Display
RELEASE ANGLE
ANGLE
TORQUE
MULTI-COLOR
STATUS LED
Green-Ready
Yellow-Busy
Red-Error
SOFT BUTTON
INDICATORS
FASTENER
TYPE
BATTERY
SOFT BUTTONS
MONITOR
ROTATION SELECT
(TIGHTEN/LOOSEN)
Setting Torque and Release Angle
Figure 14 - Setting Torque and Angle
Soft Keys
Corresponding
to Graphic
Indicators
Increase
Value
Go to Next
Screen
Press and hold center key to toggle through screens for setting Torque, Angle and Release Angle. While
on screen, use the up and down arrow keys to select value.
Decrease
Value
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
21
Basic Function Descriptions
Torque: Allows the operator to enter the target torque that the gun will seek when the trigger is pulled
and held.
Angle: If an angle setting is above “0” the gun will add this angle of rotation to a completed torque
operation using the maximum output of the unit.
Release Angle: After completing an operation, the gun will automatically run backwards the specied
angle to release windup from reaction torque. This will allow the operator to remove the tool without
loosening the fastener.
Torque and Angle Operation Caution: If the torque required to rotate the fastener through the selected
angle is unknown the torque may exceed the capacity of the tool in which case a failure warning will be
displayed: “Motor Stalled at Full Power.”
In order to determine if the tool is capable of meeting the requirement the following is suggested:
1. Tighten the fastener to the desired torque in Torque Mode.
2. Mark the position of the fastener.
3. With the tool still in Torque Mode set the tool to max output and measure how far the fastener
rotates.
4. If the fastener does not meet the angle requirement (with some margin) the torque to achieve the
angle is beyond the tools capacity and a larger tool should be used.
Note: This procedure will subject the fastener to max tool output torque. If unsure the fastener
can safely handle max torque do not perform this operation.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
22
TORQUE GUN OPERATION
Tightening
1. Use the options menu to specify the type of fastener being used.
2. Set the tool to the desired torque level.
3. Set the tool to the desired post-torque angle. (REMEMBER: the gun will apply AT LEAST its
maximum rated torque while turning the fastener through this requested angle. Accidental
application of this post-torque angle feature, or accidental retorqueing of a fastener while using
angle feature, can lead to damage of the fastener and fastened equipment.)
4. Set the tool to the desired release angle. (REMEMBER: the gun will apply AT LEAST its maximum
rated torque while turning the system in the “Loosen” direction. Depending on the reaction
arrangement of your system, and the requested release angle, this could cause the fastener itself
to loosen.)
5. Make sure the Lithium gun and fastener equipment are positioned properly.
6. Make sure the torque reaction arrangement is placed securely (HYTORC Washer, HYTORC Nut, or
Reaction Arm).
7. Pull the trigger to start the torqueing operation.
8. The tool will torque the fastener until the requested torque value is reached.
9. If a post-torque angle has been specied, the tool will turn the fastener the requested angle after
the torqueing operation.
10. If a release angle has been specied the tool will back-off the requested angle at the end of
the operation.
11. The tool will now indicate the status of the operation.
Loosening
1. Use the options menu to specify the type of fastener being used.
2. Make sure the Lithium gun and fastener equipment are positioned properly.
3. Make sure the torque reaction arrangement is placed securely (HYTORC Washer, HYTORC Nut, or
Reaction Arm).
4. Instruct the tool to loosen the fastener by pressing the center button.
CAUTION: the tool will use AT LEAST the maximum rated torque of the tool to loosen the fastener.
5. Pull the trigger to start the loosening operation.
6. Release the trigger to stop loosening the fastener.
CAUTION
In reverse direction, the torque gun is set to MAXIMUM torque setting in
order to loosen the nut. Use extreme caution when running in this mode.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
23
OPTIONS
Getting to the Options Menu
By simultaneously pressing the leftmost and center buttons and holding them, the Options menu will be
displayed. Figure 15 shows the options menu. Press the corresponding up/down arrow keys to highlight
the different selection. Press the center button to select the highlighted option.
(Press Together)
BEEPER: Turn beeper On/Off. The beeper beeps
4 times to indicate an error. It beeps 1 time for a
successful operation.
OUTPUT UNITS: Change the units to be displayed for
the torque setting. It allows the operator to select the
preferred units of torque to display.
NORMAL:The screen is legible when battery is down.
INVERT: The screen is legible when battery is up.
INVERT for CAL: The screen is inverted when calibrating.
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24
Options (Continued)
FASTENER TYPE: Allows setting of left handed or right
handed threads and sets functions accordingly. Also offers a setting for “HYTORC Nut” and “HYTORC Washer”.
SHORTCUTS: Shows the button press shortcut combinations.
DISPLAY POLARITY: Inverts the display color from
white to black (for better visibility in some lighting).
CYCLE COUNTER: Shows the number of completed,
failed, and total cycles.
CHANGE UNLOCK CODE:
Allows the user to change the
unlock code of the gun (this
code is required for entering
calibration mode and changing
either the upper or lower
torque limits). Changing some
features, such as calibration,
requires the use of an unlock
code. This function allows you
to change the code from the
default. The default code is 0.
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25
Options (Continued)
CALIBRATION: Enters the calibration routine (see “Calibration
Section” of the manual).
FW / HW VERSIONS: Shows the current hardware
and software versions of the gun.
MEMORY: Allows the user to save the
current gun parameters to a memory
location, or load gun parameters from
a memory location.
ERROR LOG: A running list of the error codes generated
by the gun.
UPPER TORQUE LIMIT: The
default Unlock Code is 0 (to
change the unlock code see
“change unlock code” option
on page 26).
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26
Options (Continued)
LOWER TORQUE LIMIT; he
default Unlock Code is 0 (to
change the unlock code see
“change unlock code” option
on page 26).
SET ANGLE DELAY: The user can adjust the time delay
between the gun reaching torque and when it starts turning
through the specied angle. This is the time that the tool
will pause between the Torque and Angle Operations.
CALIBRATION LIMIT: The user can specify the number
of operations the gun can perform before it needs to be
calibrated. When this number of operations is exceeded
the gun will warn the operator before each subsequent
operation. If set to zero this feature is disabled.
CALIBRATION SAMPLES: The user can set the
number of Calibration Samples to take per calibration
point. See the “Calibration” section of the manual.
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
27
SHORTCUTS
MAIN SCREEN BUTTON SHORTCUTS:
(Long Press)
GETTING TO THE OPTIONS MENU
(Press Together)
CALIBRATION
(Press Together)
(Long Press) (Long Press)
See “Options” Section.
This shortcut starts the calibration
routine. See “Calibration Section”.
MEMORY
(Press Together)
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
28
See “Memory” in the options section.
HYTORC WASHER OVERVIEW
The HYTORC Washer makes having a Reaction Arm unnecessary. It is sold and distributed exclusively
by HYTORC. The HYTORC Washer is a washer that ts under a standard nut and is used in conjunction
with the HYTORC Washer Driver. The nut is driven by the inner sleeve of the drive. The reaction of the
tool is transmitted to the outer sleeve of the HYTORC Washer drive.
Figure 15 - HYTORC Washer and Driver
Safety increases as there are no external moving parts. The system provides a universal HYTORC reaction point for all applications, making custom reaction arms unnecessary. The fact that the tightening
and the reaction takes place in the same axis, eliminates lateral forces, balances surface friction and
increases bolt load accuracy.
HYTORC Washer Requirements
• Always use the appropriately sized HYTORC Washer for the nuts and bolts you use.
• All specications of the connection (screw size, material, seal type, etc.) must be coordinated.
• When installing the HYTORC Washer, use only original HYTORC accessories. Never use a wrench
or other torque drive.
HYTORC Washer Assembly, Use and Service (SETUP)
Correct preparation and use of HYTORC Washers are a prerequisite for good rundown and for safe
handling.
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29
Important Preparation Steps for the HYTORC Washer
• Before using the HYTORC Washer the connection and the connection elements must be carefully
checked and cleaned.
• The HYTORC Washer must be completely dry and free from oil and grease.
• The nut to be mounted above the HYTORC Washer must be lubricated according to the
specications and application requirements.
Important Installation Steps for the HYTORC Washer
• Slide bolts through the bolt hole.
• Determine which side of the connection is more suitable for fastening and tightening the bolts.
(Working space for bolting, lighting, accessibility).
• Install the clean, dry nut on the opposite side from which you want to tighten.
• Install the HYTORC Washer on the side which you want to tighten by rotating the bolt clockwise
until it is hand tight.
• Now install the lubricated nut (on the same side as the HYTORC Washer) by turning it clockwise
until it is hand tightened against the HYTORC Washer.
Figure 16 - HYTORC Washer Installed
CAUTION
For a correct installation only 3 to 4 threads should be seen beyond the nut to
be tightened.
Once all the bolts are prepared following the previous instructions for assembly, tighten the nuts using
the HYTORC Washer Driver.
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30
Figure 17 - Installing Set Screw on HYTORC Washer Driver
Installing HYTORC Washer Driver
• The set screw for fastening the HYTORC Washer Driver is aligned with the milled recess in the ring
gear of the tool. See Figure 18 and Figure 19.
• Tighten the set screw and then loosen it again by ¼ turn.
Figure 18 - Tighten Set Screw
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31
Tightening with HYTORC Washer
• Put the tool in tightening mode.
• Put the tool in HYTORC Washer mode (Refer to the Options section)
• Place the HYTORC Washer Driver on the battery powered tool and tighten the set screw.
• Engage the HYTORC Washer Driver and tool with the nut by placing it over the top of the bolt to
be tightened.
• Repeat the steps for tightening a bolt as shown for standard torque in this manual.
Figure 19 - HYTORC Washer Driver on LITHIUM
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32
MAINTENANCE
Preventive Maintenance
Even though the LITHIUM Torque Gun can operate virtually maintenance free; good care, proper repairs
and preventive maintenance will contribute signicantly to longer lasting tool life.
• Sufcient cooling must always be ensured. The cooling vents must be kept clean, free of adhering
dirt and dust, and may not be closed for any reason.
• Keep tools clean and protected from damage.
• Have worn or damaged ttings or cords replaced.
WARNING!
During maintenance, the power supply must be disconnected.
Damaged power cables or cords can be hazardous.
CALIBRATION
Calibration should be done by a qualied technician. For standard bolting work, calibration must be
done on a soft joint xture. The LITHIUM Gun can collect and average many samples for each calibration
point.
1. Enter the desired number of samples to be taken per calibration point by changing the “Calibration
samples” value in the options menu.
2. Enter calibration mode through the Options menu or by pressing, and holding, the middle and right
buttons simultaneously.
3. Enter the unlock code (default code is “0”).
4. Enter optional release angle.
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33
5. Calibration routine will now begin: Be aware, the gun will now operate WITHOUT prompting the
operator to also press one of the back buttons.
• When “Cal Point X – Y operate gun & record torque” is displayed: (Note: X = the current
calibration point, Y = the current sample of the calibration point).
- Pull and hold the trigger.
- The gun will torque until it reaches its calibration point.
- When it stops, enter the nal torque using the rear buttons.
• The torque gun will now temporarily store this calibration point.
• Repeat at the gun prompts.
6. When all calibration points are completed, the torque gun will ask if you would like to save or
cancel. If you select “save”, the temporary calibration data will now be locked into memory.
Note: If the rst calibration point generated torque values ABOVE the minimum rated torque for the tool
you are calibrating, the calibration has failed. If by the LAST calibration point, the gun failed to generate
torque that EXCEEDS the maximum rated torque of the gun, the calibration has failed. In either case
please contact The Torque Gun Company for support.
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34
APPENDIX A
LITHIUM GUN BLOCK DIAGRAM
Figure 20 - Lithium GUN Block Diagram
POWER IN
36V DC
MOTOR DRIVE
MOTOR
TRIGGER
SWITCH
CONTROLLER BOARD
(MDC)
USER INTERFACE
CONTROLLER
BOARD (UIC)
GEAR
BOX
SOCKET
DRIVE
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35
APPENDIX B
MODEL BTM-0250 BTM-0700 BTM-1000 BTM-2000 BTM-3000
TORQUE RANGE
34-325 ft-lbs.(47-
441 Nm)
150-700 ft-lbs.
(203-949 Nm)
200-1200 ft-lbs.
(271-1627 Nm)
325-2000 ft-lbs.
(339-2711 Nm)
500-3000 ft-lbs.
(678-4067 Nm)
DRIVE SIZE ½" SQ. ¾” SQ. ¾” SQ. 1” SQ. 1” SQ.
HEIGHT (H) 12.85” (32.6 cm) 12.85” (32.6 cm) 12.85” (32.6 cm) 13.20” (33.5 cm) 13.20” (33.5 cm)
LENGTH (L) 10.12” (25.7 cm) 11.12” (28.2 cm) 11.44” (29.0 cm) 13.29” (33.8 cm) 13.54” (34.4)
WIDTH (W) 3.47” (8.8 cm) 3.47” (8.8 cm) 3.47” (8.8 cm) 3.47” (8.8 cm) 3.47” (8.4 cm)
RADUIS 1.12” (2.8 cm) 1.59” (4.0 cm) 1.59” (4.0 cm) 1.75” (4.4 cm) 1.75” (4.4 cm)
ARM LENGTH 2.75” (7.0 cm) 2.75” (7.0 cm) 2.75” (7.0 cm) 3.5” (8.9 cm) 3.5” (8.9cm)
ARM RADUIS 4.19” (10.6 cm) 4.55” (11.4 cm) 4.55” (11.4 cm) 6.18” (15.7 cm) 6.18” (11.4 cm)
WEIGHT
WITH BATTERY
9.52 lbs (4.32 kg) 10.2 lbs (4.63 kg) 10.6 lbs (4.81 kg) 14.2 lbs (6.44 kg) 15.6 lbs
RUNDOWN RPM
(NO LOAD)
180 RPM 85 RPM 40 RPM 23 RPM 15 RPM
FINAL TORQUE RPM 17 RPM 8.5 RPM 4 RPM 1.8 RPM 1.6 RPM
LITHIUM GUN DIMENSIONS
Figure 21 - Lithium Gun Dimensions
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
36
BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING
37
BREAKTHROUGH PRODUCTS
Find your nearest TORQUE GUN CO. distributor at
FOR INDUSTRIAL BOLTING
www.torquegun.com/dist
120 Wesley Street, Hackensack, New Jersey 07606 U.S.A.
Tel: 201-512-9800 • E-Mail: info@torcgun.com • Web: www.torquegun.com
888-GUN-2-GUN
TORQUE GUN
A HYTORC COMPANY
MAN-TGC-LITGUN-2017
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