jGun pneumatic socket wrench
Technical manual
Introduction
Copyright
©
2016 HYTORC. All rights reserved.
This document or parts thereof may not be reproduced, copied, distributed, stored in a retrieval
system, or transmitted, in any form or by any means, electronically nor otherwise, without the prior
written consent of HYTORC.
Specifications and illustrations are subject to change without prior notice. HYTORC will not accept
liability for any alteration or typing error. Details and values given in this manual are average
values and have been compiled with care. Details and values are not binding. HYTORC disclaims
any liability for damage or detriments suffered as a result of reliance on the information given
herein or the use of products, processes or equipment to which this document refers.
2
Contents
Contents
1 About the document.................................................................................6
1.1 Purpose of the document.............................................................................................................6
1.2 How to work with the document...................................................................................................6
1.3 Languages................................................................................................................................... 6
1.4 Illustrations...................................................................................................................................6
1.5 Safety symbols in the document..................................................................................................6
1.6 Related documents......................................................................................................................7
1.7 Revision history............................................................................................................................7
1.8 Contact information......................................................................................................................7
2 Safety.......................................................................................................8
2.1 General safety instructions.......................................................................................................... 8
2.1.1 Personnel..........................................................................................................................8
2.1.2 Work area..........................................................................................................................8
2.1.3 Equipment.........................................................................................................................8
2.2 Additional safety instructions....................................................................................................... 9
2.2.1 FRL................................................................................................................................... 9
2.2.2 Pneumatic hoses...............................................................................................................9
2.2.3 Reaction arms...................................................................................................................9
2.2.4 Sockets........................................................................................................................... 10
2.3 Safety symbols on the tool.........................................................................................................11
2.4 Qualified personnel....................................................................................................................11
2.5 Liability.......................................................................................................................................11
3 Description............................................................................................. 12
3.1 Intended use.............................................................................................................................. 12
3.2 Overview....................................................................................................................................12
3.3 Filter regulator lubricator (FRL)..................................................................................................12
3.4 Pneumatic socket wrench..........................................................................................................14
3.5 Accessories................................................................................................................................14
3.5.1 Safety lever..................................................................................................................... 14
3.5.2 Low-noise muffler............................................................................................................15
3.5.3 Silencer system...............................................................................................................16
3.5.4 BoltSafe load tester.........................................................................................................16
4 Installation..............................................................................................18
4.1 Pneumatic hoses....................................................................................................................... 18
4.1.1 Pneumatic hose connections.......................................................................................... 18
4.1.2 Connecting the pneumatic hoses....................................................................................18
4.1.3 Disconnecting the pneumatic hoses............................................................................... 19
4.2 Connecting the air supply.......................................................................................................... 19
5 Reaction arms........................................................................................21
5.1 Standard reaction arm (360°).................................................................................................... 21
5.2 Standard reaction arm (360° x 360°)......................................................................................... 21
5.3 Straight TPF reaction arm..........................................................................................................22
5.4 Straight WTCT reaction arm with reaction cup.......................................................................... 23
- - 3
Contents
5.5 Curved WTCT reaction arm with reaction pin cup..................................................................... 23
5.6 Curved reaction arm with dual-end reaction cup....................................................................... 24
5.7 Reaction arm for recessed installation.......................................................................................24
5.7.1 Fixed length.....................................................................................................................24
5.7.2 Adjustable length.............................................................................................................25
5.8 Straight dual-tool interconnect reaction arm.............................................................................. 25
5.9 U-shaped dual-tool interconnect reaction arm...........................................................................26
5.10 Multi-tool interconnect reaction arm...........................................................................................26
5.11 Reaction ring..............................................................................................................................27
5.12 Reaction strip (recessed bolt heads)......................................................................................... 28
5.13 HYTORC Washer™ double-drive socket................................................................................... 28
5.14 HYTORC LoadDISC™ double-drive socket...............................................................................28
5.15 HYTORC Nut™ drive................................................................................................................. 29
5.16 Offset-link...................................................................................................................................30
6 Securing the sockets and reaction arms................................................31
6.1 Securing the socket (type 1)...................................................................................................... 31
6.2 Securing the sockets (type 2).................................................................................................... 32
6.3 Securing the reaction arm onto the spline shaft.........................................................................32
7 Operation............................................................................................... 33
7.1 Inspections before use...............................................................................................................33
7.2 Determining the gearbox mode (Dual Speed and Nut Runner).................................................33
7.3 Torque........................................................................................................................................34
7.3.1 Pressure/torque chart......................................................................................................34
7.3.2 Setting the torque............................................................................................................34
7.4 Direction of rotation....................................................................................................................35
7.4.1 Determining the direction of rotation............................................................................... 35
7.4.2 Changing the direction of rotation................................................................................... 35
7.5 Tightening and loosening a bolted flange connection................................................................35
7.5.1 Tightening a bolted flange connection............................................................................ 36
7.5.2 Loosening a bolted flange connection.............................................................................36
8 Maintenance.......................................................................................... 37
8.1 Preventive maintenance............................................................................................................ 37
8.2 Maintenance by HYTORC......................................................................................................... 37
8.3 Filling the oil filter reservoir........................................................................................................ 37
8.4 Draining the water filter reservoir manually................................................................................37
9 Troubleshooting..................................................................................... 39
10 Technical data........................................................................................40
10.1 Single Speed..............................................................................................................................40
10.1.1 jGun J-.25........................................................................................................................40
10.1.2 jGun J-.5..........................................................................................................................40
10.1.3 jGun J-1...........................................................................................................................41
10.1.4 jGun J-2...........................................................................................................................41
10.1.5 jGun J-3...........................................................................................................................41
10.1.6 jGun J-5...........................................................................................................................41
10.1.7 jGun J-8...........................................................................................................................42
10.2 Dual Speed................................................................................................................................ 42
4 - -
Contents
10.2.1 jGun DSP-.5.................................................................................................................... 42
10.2.2 jGun DSP-1..................................................................................................................... 43
10.2.3 jGun DSP-2..................................................................................................................... 43
10.2.4 jGun DSP-3..................................................................................................................... 43
10.2.5 jGun DSP-5..................................................................................................................... 43
10.2.6 jGun DSP-8..................................................................................................................... 44
10.3 Nut Runner.................................................................................................................................44
10.3.1 jGun J-A1-AP-WG...........................................................................................................44
10.3.2 jGun A1-Z........................................................................................................................45
10.4 Physical conditions.................................................................................................................... 45
10.5 Maximum torque values (male hex sockets)..............................................................................45
11 Declaration of Conformity...................................................................... 47
- - 5
About the document
1 About the document
1.1 Purpose of the document
The document shows the information to do these steps:
• Install the equipment
• Operate the equipment
• Maintain the equipment
The document contains the original instructions for the jGun pneumatic socket wrench, to
which is referred with the term ‘tool’. The term ‘equipment’ is used as a more general term
to refer to the entire system: the tool, its parts and its accessories, including the FRL.
1.2 How to work with the document
1. Read the document completely. Make sure that you understand all the instructions.
2. Obey the safety instructions to prevent injury or damage to equipment.
3. Do the procedures completely and in the given sequence.
4. Keep a copy of the latest version of the document and all related documents near the
equipment.
1.3 Languages
The original language of the document is English. All other language versions are
translations of the original instructions.
1.4 Illustrations
It is not always possible to provide a detailed illustration of every single item of the
equipment. The illustrations in the document show a typical setup and are for instructional
use only.
1.5 Safety symbols in the document
Safety symbol
Function Description
Warning “Warning” means that injury or death is possible if you
do not obey the instructions.
Caution “Caution” means that damage to equipment is possible
if you do not obey the instructions.
Note “Note” is used to give additional information.
6 47 - 001 -
1.6 Related documents
Document name Target group
jGun pneumatic socket wrench
User manual
1.7 Revision history
Date Revision number Comment
01-12-2016 001 First version
1.8 Contact information
About the document
Personnel who operates the equipment
HYTORC Nederland BV
Platinawerf 8
6641 TL Beuningen
The Netherlands
Phone: +31 (0)24 3660660
Website: www.hytorc.nl
Email: info@hytorc.nl
HYTORC Benelux BVBA
Ysselaarlaan 65B
2630 Aartselaar
Belgium
Phone: +32 (0)38 705220
Website: www.hytorc.be
Email: info@hytorc.be
47 - 001 - 7
Safety
2 Safety
2.1 General safety instructions
2.1.1 Personnel
• Do not allow unqualified personnel to perform tasks on or with the equipment.
• Keep unqualified personnel, children and animals away from the equipment.
• Wear personal protective equipment (PPE): safety helmet, safety goggles, hearing
protection, safety gloves, safety shoes and coverall.
• Wear hearing protection. The sound emission of a standard tool is approximately 95
dB.
• Keep loose clothing, long hair and jewelry away from the moving parts.
• Stay alert. Use common sense. Do not use the equipment under the influence of
mood-altering substances.
• Always stand in a firm position.
• Keep your hands away from the nut or the bolt being loosened or tightened.
• Do not stand in the line of movement of the tool during operation. If the tool separates
from the nut or the bolt, it will detach in that direction.
• Be aware that a fastener that breaks off during operation will become a high-velocity
projectile.
• Obey the local labor and safety laws and environmental regulations.
2.1.2 Work area
• Keep the work area clean and well lit.
• Keep the work area free of unwanted obstacles. Ensure free passages in the work
area during operation.
2.1.3 Equipment
• Only use equipment that is approved by HYTORC.
• Only use equipment that is appropriate or compatible with the HYTORC equipment.
• Do not modify the equipment in any way.
• Only use the tools for the purposes for which they have been designed. Do not force
small tools or accessories to do the job of a larger tool. HYTORC can develop
customized accessories to ensure safe and simple operation. Contact your local
HYTORC representative for more information.
• Inspect the equipment for visual damage before each use. Obey the instructions for
maintenance of the equipment.
• Do not remove or disable the safety provisions on the equipment.
• Make sure that the cover plates are not damaged and installed correctly. All HYTORC
tools are equipped with cover plates to cover moving parts. If cover plates are missing
or damaged, contact your local HYTORC representative for repair.
• Do not apply more pressure to the equipment than the maximum allowable pressure.
• Do not hit reaction arms or sockets with heavy objects (e.g. hammers). If the nut or the
bolt does not turn with the tool you are using, use a tool of a larger size.
• Do not cut, weld or otherwise modify reaction arms or sockets.
• Do not expose reaction arms or sockets to extremely high or low temperatures.
• Do not leave tools with reaction arms and sockets hanging on the nut or the bolt.
8 47 - 001 -
• Do not use FRLs, pneumatic hoses, hose connections with hose couplings, power
cables or remote control cables to carry or move the equipment. Always hold the FRL
or the tool to carry or move the equipment.
• Store tools and accessories which are not in use properly.
2.2 Additional safety instructions
2.2.1 FRL
• Only use HYTORC FRLs.
• Do not modify the FRL in any way.
• Metal-to-metal contact can cause sparks. Take appropriate additional measures.
• Make sure that the air supply pressure is between 6.2 bar (90 psi) and 10 bar (145
psi).
• Make sure that the maximum outgoing operating pressure of the FRL is not higher
than the maximum permitted pressure of 6.2 bar (90 psi).
• Make sure that the FRL is filled with the (supplied) lubricating oil (Shell Tellus S2 VX
32).
• Make sure that the oil level in the oil filter reservoir is beween the minimum mark and
the maximum mark. Use the oil level sight glasses to check the oil level.
• Do not mix different grades of lubrication oil.
• Make sure that the oil filler cap is placed on the oil filling point.
Safety
2.2.2 Pneumatic hoses
• Only use HYTORC pneumatic hoses.
• Do not modify the pneumatic hoses in any way.
• Make sure that the pneumatic hoses are securely connected.
• Make sure that the pneumatic hoses are not kinked or twisted.
• Keep the pneumatic hoses away from the reaction point.
• Replace damaged pneumatic hoses immediately. Replace the pneumatic hoses at
least every three years.
2.2.3 Reaction arms
• Only use HYTORC reaction arms.
• Do not modify the reaction arms in any way.
• Place the reaction arm against a solid reaction point that can handle the load.
• Only place the reaction area against the reaction point.
47 - 001 - 9
ุPP
Safety
• Make sure that the end of the reaction arm has both horizontally and vertically at least
10 mm overlap with the reaction point. If a distance of at least 10 mm is not possible,
choose another reaction point or use an appropriate reaction arm.
• Make sure that the reaction arm is locked onto the spline of the tool.
• Avoid excessive play. Pressurize the system momentarily. If the tool tends to creep or
stand askew, stop immediately and adjust the reaction arm to a more solid and secure
position.
• Do not place the reaction arm against a round or inclined reaction point.
• Do not place any part of your body between the reaction arm and the reaction point.
• Do not place objects between the reaction arm and the reaction point.
• When you use a reaction cup, make sure that the reaction cup is placed over the
reaction point completely.
• When you use a reaction pin cup, make sure that the pin reaches the bottom of the
hex bolt.
2.2.4 Sockets
• Only use HYTORC sockets.
• Do not modify the sockets in any way.
• Do not use sockets that have been excessively heated or cooled.
• Use thick-walled heavy-duty sockets only. Do not use thin-walled sockets.
• Only use deep well sockets when strictly necessary. The excessive height causes
unnecessary bending forces.
• Do not use sockets that are used on impact wrenches. The impact deforms the drive
hole of the socket and hardens and brittles the steel. This can cause fracture of the
steel and increases the risk of flying objects.
• Make sure that the width across flats of the socket corresponds to the width across
flats of the nut or the bolt. Note the difference between metric and imperial
measurements.
• Place the tool with the socket on the nut or the bolt. Make sure that the socket is
placed over the nut or the bolt as far as possible.
• Make sure that the socket is secured to the tool.
• Do not use common extension pieces or step-up/step-down adapters. HYTORC can
develop customized accessories to ensure safe and simple operation. Contact your
local HYTORC representative for more information.
10 47 - 001 -
2.3 Safety symbols on the tool
The tool has no warning labels. Warning labels can only be applied on locations where
they will become damaged or illegible immediately.
2.4 Qualified personnel
The term ‘qualified personnel’ refers to persons who thoroughly understand the
equipment and its safe installation, operation and maintenance. Qualified personnel are
physically capable of performing the required tasks, familiar with all relevant safety
instructions and regulations and trained to safely install, operate and maintain the
equipment. It is the responsibility of the company operating the equipment to see that the
personnel meet these requirements.
2.5 Liability
HYTORC cannot be held responsible for injury or damage that results from unintended
use of the equipment. The equipment is designed and intended only for the purpose
described in the relevant documents. Uses not described in the relevant documents are
considered unintended uses and can result in injury or damage.
Safety
Unintended uses include:
• Using equipment that is not approved by HYTORC
• Using equipment that is inappropriate or incompatible with the HYTORC equipment
• Altering or modifying equipment in any way
• Allowing unqualified personnel to perform tasks on or with the equipment
47 - 001 - 11
31
2
Description
3 Description
3.1 Intended use
The jGun pneumatic socket wrench is a tool used for both your torque and tension
applications. Different reaction arms and sockets can be used with the tool. HYTORC
pneumatic tools have a repeatable accuracy of ± 5%. The air consumption is up to 1,500
l/min.
3.2 Overview
1
Filter regulator lubricator (FRL) 3 Pneumatic socket wrench
2 Pneumatic hose
3.3 Filter regulator lubricator (FRL)
The FRL collects water and oil from the air supply to prevent contamination of the tool.
The pressure range of the FRL is 1 bar - 7 bar.
12 47 - 001 -
1
2
4
5
3
6
Description
1 Air pressure regulator 4 Oil filter reservoir
2 Air lubrication knob 5 Water filter reservoir
3 Switch of oil filter reservoir 6 Compressed air inlet
47 - 001 - 13
6
1
2
4
5
3
Description
3.4 Pneumatic socket wrench
1 Hose connection 4 Square drive for socket connection
2 Air exhaust 5 Spline for connection of reaction arm
3 Trigger switch 6 Tighten/loosen switch
3.5 Accessories
3.5.1 Safety lever
The safety lever makes sure that the tool is always used with both hands and therefore
reduces the risk of injury. When you pull the trigger switch, one hand must push the
safety lever to keep hands away from moving parts and the bolt or nut.
14 47 - 001 -
Procedure
A
B
1. Push and hold the safety lever.
2. Pull the trigger switch.
3.5.2 Low-noise muffler
The low-noise muffler decreases the sound emission of the tool to 80 dB.
Description
Caution:
• HYTORC recommends to calibrate the tool after:
• the modification of the tool.
• the replacement of the low-noise muffler.
The low-noise muffler has an effect on the torque output.
• Replace the low-noise muffler when it is discolored, clogged or after every
five hours of operation.
Procedure
1. Remove the low-noise muffler (A)
from the bottom plate (B).
2. Install the new low-noise muffler
(A).
When you must replace the low-noise muffler, refer to the table below to select and order the correct part number.
47 - 001 - 15
B
A
Description
Part number 10187723 Part number 10138922
J-.25 DSP-.25 J-5 DSP-5
J-.5 DSP-.5 J-8 DSP-8
J-1 DSP-1
J-2 DSP-2
J-3 DSP-3
3.5.3 Silencer system
Caution:
• Do not modify the silencer system in any way.
• Only use a single silencer system hose with a maximum length of 4 m (13
ft.).
The silencer system reduces the sound emission to approximately 75 dB. The silencer
system has two parts:
• the exhaust silencer (A)
• the silencer system hose (B)
Procedure
1. Connect the silencer system hose
(B) to the FRL and the tool.
3.5.4 BoltSafe load tester
The BoltSafe load tester has a reading system and one or more sensors. The BoltSafe
load tester helps to find the correct tool setting for the used bolt. The sensors are shaped
and used as a regular washer. Different BoltSafe read-out systems are available for
continuous and periodic measurement.
16 47 - 001 -
Procedure
1. Place the BoltSafe load tester
between the nut and mounting
surface.
Description
47 - 001 - 17
$
%
Installation
4 Installation
4.1 Pneumatic hoses
The working pressure of the pneumatic hoses is up to 6.2 bar. The safety factor of the
pneumatic hoses is factor 4.
4.1.1 Pneumatic hose connections
Use a single pneumatic hose with a maximum length of 4 m (13 ft.) to connect the FRL to
the tool.
Caution:
• Do not modify the pneumatic hoses in any way. If you modify the
pneumatic hoses, damage to the equipment can occur.
Quick safety couplings (JGUN-FRLJA0034FHB)
• To tighten the couplings, make sure that the
system is depressurized. Pull back the pullback ring on the female coupling (B), push
the male coupling (A) into the female coupling (B) and release the pull-back ring.
• To loosen the couplings, make sure that the
system is depressurized. Pull back the pullback ring on the female coupling (B), pull the
male coupling (A) from the female coupling
(B) and release the pull-back ring.
4.1.2 Connecting the pneumatic hoses
Warning:
• Make sure that the system is depressurized.
• Make sure that the pneumatic hose is securely connected to both the FRL
and the tool. Make sure that there is no clearance between the couplings.
If the pneumatic hose becomes loose, no air or lubrication oil will flow
through the hoses and the tool will not operate.
18 47 - 001 -
Procedure
1. If the hose couplings are dirty, clean
them with a lint-free cloth.
2. Fully tighten the couplings.
3. Manually tighten the hose
couplings. Do not use pliers.
4.1.3 Disconnecting the pneumatic hoses
Warning:
Installation
• Make sure that the system is depressurized.
Procedure
1. Disconnect the pneumatic hose
from the FRL and the tool.
2. Disconnect the supply hose from
the air supply and the FRL.
3. Roll up the pneumatic hoses and
connect the hose couplings to
prevent them from becoming soiled.
4.2 Connecting the air supply
Warning:
• When you operate the tool in areas with explosion hazard, use nitrogen
instead of air. Contact your local HYTORC representative for more
information.
47 - 001 - 19
A
B
C
D
E
F
Installation
Procedure
1. Connect the air supply to the
compressed air inlet (F). Use an air
hose with an internal diameter
larger than 3/4". HYTORC
recommends to use an air hose
with an internal diameter of 1".
Note:
• The air supply
pressure must be
between 6.2 bar (90
psi) and 10 bar (145
psi) at a maximum
air consumption of
1,500 l/min.
20 47 - 001 -
5 Reaction arms
+\GUDXOLF (OHFWULF 3QHXPDWLF
The reaction arms can be used together with hydraulic tools, pneumatic tools and electric
tools.
There are different types of reaction arms to operate the tool.
5.1 Standard reaction arm (360°)
The length of the reaction arm is fixed. One standard heavy-duty socket must be used
together with the reaction arm.
Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Place the tool as shown.
Reaction arms
5.2 Standard reaction arm (360° x 360°)
The length of the reaction arm is fixed. The height of the reaction arm is adjustable. One
47 - 001 - 21
standard heavy-duty socket must be used together with the reaction arm.
Note:
The best reaction point is immediately above the flange surface. When the
reaction point is higher we recommend to limit the torque output to the
percentages as shown.
Reacting higher creates unwanted bending forces in the boltshaft and the
bolting tool. Avoid these bending forces to improve torque- and boltload
accuracy, and to improve durability of the tool and socket driver (especially for
allen hex sockets).
+\GUDXOLF (OHFWULF 3QHXPDWLF
+\GUDXOLF (OHFWULF 3QHXPDWLF
Reaction arms
Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Adjust the reaction arm as close to
the flange surface as possible.
4. Place the tool as shown.
5.3 Straight TPF reaction arm
The length of the reaction arm is adjustable. Two standard heavy-duty sockets must be
used together with the reaction arm.
Procedure
1. Place the sockets over the nuts as
far as possible.
2. Place the reaction arm as shown.
3. For the lowest reaction force,
choose a reaction point as far away
as possible.
4. Make sure that the reaction socket
used is placed over the reaction
point completely.
5. Place the tool as shown.
6. For more convenience, place the
safety handle as shown.
22 47 - 001 -
5.4 Straight WTCT reaction arm with reaction cup
+\GUDXOLF (OHFWULF 3QHXPDWLF
+\GUDXOLF (OHFWULF 3QHXPDWLF
The length of the reaction arm is adjustable. One standard heavy-duty socket must be
used together with the reaction arm.
Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. For the lowest reaction force,
choose a reaction point as far away
as possible.
4. Make sure that the reaction pin cup
is placed over the reaction point
completely.
5. Place the tool as shown.
6. For more convenience, place the
safety handle as shown.
Reaction arms
5.5 Curved WTCT reaction arm with reaction pin cup
The length of the reaction arm is adjustable. One standard heavy-duty hex socket must
be used together with the reaction arm.
Procedure
1. Place the male hex socket in the
bolt head as far as possible.
2. Place the reaction arm as shown.
3. For the lowest reaction force,
choose a reaction point as far away
as possible.
4. Make sure that the reaction pin cup
is placed into the bolt head
completely.
5. Place the tool as shown.
6. For more convenience, place the
safety handle as shown.
47 - 001 - 23
+\GUDXOLF (OHFWULF 3QHXPDWLF
Reaction arms
5.6 Curved reaction arm with dual-end reaction cup
The length of the reaction arm is fixed.
Procedure
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Make sure that the reaction cups
are placed over the reaction points
completely.
4. Place the tool as shown.
5.7 Reaction arm for recessed installation
5.7.1 Fixed length
The length of the reaction arm is fixed. One standard heavy-duty socket must be used
together with the reaction arm.
24 47 - 001 -
Procedure
+\GUDXOLF (OHFWULF 3QHXPDWLF
+\GUDXOLF (OHFWULF 3QHXPDWLF
1. Place the socket over the nut as far
as possible.
2. Place the reaction arm as shown.
3. Place the tool as shown.
Reaction arms
5.7.2 Adjustable length
The length of the reaction arm is adjustable. One standard heavy-duty socket must be
used together with the reaction arm.
Procedure
1. Loosen the lock nut.
2. Place the socket over the nut as far
as possible.
3. Tighten the lock nut.
4. Place the reaction arm as shown.
5. Place the tool as shown.
5.8 Straight dual-tool interconnect reaction arm
The length of the reaction arm is adjustable. Two standard heavy-duty sockets must be
used together with the reaction arm.
47 - 001 - 25
+\GUDXOLF (OHFWULF 3QHXPDWLF
+\GUDXOLF (OHFWULF 3QHXPDWLF
Reaction arms
Procedure
1. For the lowest reaction force,
choose a reaction point as far away
as possible.
2. Place the reaction arm as shown.
3. Place the sockets over the nuts as
far as possible.
4. Place the tools as shown.
5.9 U-shaped dual-tool interconnect reaction arm
The length of the reaction arm is adjustable. Two standard heavy-duty sockets must be
used together with the reaction arm.
Procedure
1. For the lowest reaction force,
choose a reaction point as far away
as possible.
2. Place the reaction arm as shown.
3. Place the sockets over the nuts as
far as possible.
4. Place the tools as shown.
5.10 Multi-tool interconnect reaction arm
Multiple standard heavy-duty sockets must be used together with the reaction arm.
26 47 - 001 -
Procedure
+\GUDXOLF (OHFWULF 3QHXPDWLF
+\GUDXOLF (OHFWULF 3QHXPDWLF
1. Place the sockets over the nuts as
far as possible.
2. Place the reaction arm as shown.
3. Place the tools as shown.
Reaction arms
5.11 Reaction ring
Multiple standard heavy-duty sockets must be used together with the reaction arm.
Procedure
1. Place the sockets over the nuts as
far as possible.
2. Place the reaction arm as shown.
3. Place the tools as shown.
47 - 001 - 27
+\GUDXOLF (OHFWULF 3QHXPDWLF
+\GUDXOLF (OHFWULF 3QHXPDWLF
Reaction arms
5.12 Reaction strip (recessed bolt heads)
Procedure
1. Place the drive into the nut as far as
possible.
2. Place the reaction arm as shown.
3. Place the tool as shown.
5.13 HYTORC Washer™ double-drive socket
Procedure
1. Place the HYTORC Washer
under the regular nut.
2. Place the double-drive socket with
the tool over the nut and reaction
washer completely.
™
5.14 HYTORC LoadDISC™ double-drive socket
The HYTORC LoadDISC™ double-drive socket allows for inverted hands-free operation.
28 47 - 001 -
Procedure
+\GUDXOLF (OHFWULF 3QHXPDWLF
+\GUDXOLF (OHFWULF 3QHXPDWLF
Reaction arms
1. Place the HYTORC LoadDISC
under the regular nut.
2. Place the double-drive socket with
the tool over the nut and reaction
washer completely.
3. Lock the double-drive socket with
the tool onto the reaction washer
using the locking lever.
5.15 HYTORC Nut™ drive
™
The HYTORC Nut™ drive allows for 100% torsion-free axial bolt loading and converts the
torque wrench into a mechanical tensioner.
Procedure
1. Replace the regular nut with the
HYTORC Nut™.
47 - 001 - 29
+\GUDXOLF (OHFWULF 3QHXPDWLF
Reaction arms
5.16 Offset-link
Procedure
1. Place the offset-link over the nut.
2. Place the reaction arm as shown.
3. Place the tool as shown.
30 47 - 001 -
&
$ %
Securing the sockets and reaction arms
6 Securing the sockets and reaction arms
Sockets and reaction arms must be secured to prevent injuries and damage to the
equipment.
There are different types of heavy-duty sockets to use with the tool:
1. 6-point sockets / 12-point sockets (regular / high)
2. 6-point hex sockets / 12-point hex sockets (regular / high)
3. Eccentric sockets
4. Customized sockets
The heavy-duty sockets are available in the sizes 1/2", 3/4", 1", 1 1/2", 2 1/2" and 3 1/2".
Warning:
• Do not use sockets that are used on impact wrenches.
6.1 Securing the socket (type 1)
Procedure
1. Slide the securing pin (B) into the
socket (A) as shown.
2. Fit the rubber ring (C) to the socket
(A) as shown.
47 - 001 - 31
$ %
&
$
%
'
Securing the sockets and reaction arms
6.2 Securing the sockets (type 2)
Procedure
1. Fit the securing clip (B) to the
socket (A) as shown.
6.3 Securing the reaction arm onto the spline shaft
Procedure
1. Slide the reaction arm (A) over the
drive shaft (B) as shown. Make sure
that the hex bolt (C) aligns with the
hole (D).
2. Tighten the hex bolt (C) using a hex
key.
32 47 - 001 -
7 Operation
C
A
B
D
E
F
7.1 Inspections before use
Make sure that:
• the air supply is correct.
• the air supply is fully unrolled and not kinked, twisted or damaged.
• all couplings and other connections are tight and not damaged or deformed.
• the pneumatic hoses are securely connected and not kinked, twisted or damaged.
• all moving parts of the tool are clean and sufficiently lubricated with a high-quality
lubricating oil (Shell Tellus S2 VX 32).
• the oil level in the oil filter reservoir is between the minimum mark and the maximum
mark.
• the air lubrication knob is set to four drops per 60-90 seconds.
• the reaction arm is placed against a solid reaction point and secured to the tool.
• the socket has the correct size and is secured to the tool.
• all securing clips, securing pins and securing screws are fitted and secured to the air
supply, FRL, the pneumatic hoses, the tool, the reaction arm and the socket.
• all water, if present, is drained from the filter reservoir.
• the pressure gauge does not leak. Signs of leakage are a decrease in the level of
glycerin in the pressure gauge or the pressure gauge filled with lubrication oil.
Operation
7.2 Determining the gearbox mode (Dual Speed and Nut Runner)
The tool has a gearbox with two modes that are shown by a sticker:
• Rundown Mode: Select this mode to run a nut into the position for final torqueing.
• Torque Mode: Select this mode for final torqueing.
Procedure
1. To select Rundown Mode, set the
gearbox switch (F) to the
RUNDOWN position.
a) Push and turn the gearbox
switch (F) counterclockwise
towards the square drive (D).
The blue line is shown.
b) When the gearbox switch (F)
does not engage, pull the
trigger switch (A) briefly.
2. To select Torque Mode, set the
gearbox switch (F) to the TORQUE
position.
a) Pull and turn the gearbox
switch (F) clockwise away from
the square drive (D).
The red line is shown.
b) When the gearbox switch (F) does not engage, pull the trigger switch (A) briefly.
47 - 001 - 33
A
B
C
D
E
F
Operation
7.3 Torque
7.3.1 Pressure/torque chart
The maximum operating pressure for all HYTORC FRLs is 6.2 bar (90 psi).
Warning:
• Make sure that the maximum operating pressure of the FRL is not higher
than the maximum permitted pressure of 6.2 bar (90 psi).
Each HYTORC torque wrench has its own pressure/torque chart. The pressure/torque
chart is separately supplied with your HYTORC torque wrench. Refer to the pressure/
torque chart to find the required torque (Nm / ft.lb.) and read the required pressure (bar /
psi).
Example (Single Speed 1)
Pressure
bar psi Nm ft.lb.
4.1 60 1,003 740
4.5 65 1,085 800
4.8 70 1,167 861
5.2 75 1,249 921
5.5 80 1,330 981
5.9 85 1,412 1042
6.2 90 1,494 1102
7.3.2 Setting the torque
Warning:
• Always set the pressure from low pressure to high pressure.
Procedure
1. Turn the air pressure regulator (A)
counterclockwise to set the
pressure as low as possible.
2. Put the tool on the ground or on
another safe location.
3. Start the air supply.
4. Turn the air pressure regulator (A)
until the pressure gauge shows the
correct pressure.
Torque
Note: Wait 15 seconds
to let the pressure
gauge adjust itself fully.
34 47 - 001 -
7.4 Direction of rotation
LOOSEN
TIGHTEN
A
7.4.1 Determining the direction of rotation
Caution:
• When you use fasteners with a left handed thread, the directions of
LOOSEN and TIGHTEN are the opposite.
Procedure
1. To tighten a bolted connection,
place the tool onto the bolt as
shown.
2. To loosen a bolted connection,
place the tool onto the bolt as
shown.
Operation
7.4.2 Changing the direction of rotation
Procedure
1. To tighten a bolted connection, set
the loosen/tighten switch (A) to "T".
2. To loosen a bolted connection, set
the loosen/tighten switch (A) to "L".
7.5 Tightening and loosening a bolted flange connection
Warning:
• When you use a hex socket, do not use more than the specified torque.
• Place the tool with the socket on the nut or the bolt. Make sure that the
socket is placed over the nut or the bolt as far as possible. Obey the safety
instructions for sockets.
47 - 001 - 35
A
A
Operation
• Place the reaction arm against a solid reaction point that can handle the
load. Obey the safety instructions for reaction arms.
• Make sure that the tool is free of the reaction point and other obstructions.
• Start the system momentarily. If the tool tends to creep or stand askew,
stop immediately and adjust the reaction arm to a more solid and secure
position.
7.5.1 Tightening a bolted flange connection
Procedure
1. Set the torque.
2. Make sure that the direction of
rotation is set correctly.
3. Place the tool onto the nut or the
bolt head correctly.
4. Pull and hold the trigger switch (A)
until the socket no longer turns.
5. Release the trigger switch (A).
7.5.2 Loosening a bolted flange connection
Caution:
• Always set the pressure as low as possible to loosen the nut or bolt.
• If you must constantly use a high torque to loosen the nut or the bolt, use a
heavier HYTORC tool. Contact your local HYTORC representative for
more information.
Procedure
1. Make sure that the direction of
rotation is set correctly.
2. Place the tool onto the nut or the
bolt correctly.
3. Pull and hold the trigger switch (A).
Hold the switch until you can loosen
the nut or the bolt by hand.
4. Release the trigger switch (A).
36 47 - 001 -
8 Maintenance
A
B
C
D
E
F
8.1 Preventive maintenance
• Clean the filter of the FRL at least 3 times a year or more often if the FRL is used daily
or in a dirty environment.
• Make sure that the tool are free of dirt and dust.
• Clean dirty hose couplings. Replace defective hose couplings.
8.2 Maintenance by HYTORC
• Have the tool disassembled, cleaned, inspected and lubricated at least once a year.
• When the tool is dirty because of sand or another abrasive, have the tool fully
disassembled, cleaned, inspected and lubricated immediately.
• Have the pressure gauge calibrated and refilled with glycerin at least once a year.
8.3 Filling the oil filter reservoir
Maintenance
Procedure
1. Move and hold the switch of the oil
filter reservoir (C) downwards.
2. Hold and turn the oil filter reservoir
(D) 40° to the left or to the right.
3. Remove the oil filter reservoir (D)
and release the switch of the oil
filter reservoir (C).
4. Fill the oil filter reservoir (D) halfway
with oil (Shell Tellus S2 VX 32).
5. Move and hold the switch of the oil
filter reservoir (C) downwards.
6. Install the oil filter reservoir (D) and
Release the switch of the oil filter
reservoir (C).
7. Hold and turn the oil filter reservoir
(D) towards the front of the FRL until you hear a click.
8. Start the air supply.
9. While you operate the tool, set the air lubrication knob (B) to four drops per 60-90
seconds.
8.4 Draining the water filter reservoir manually
There are two drain types for the water filter reservoir:
• Automatic: When you do not pull the trigger switch during operation, the water filter
• Manual: The water filter reservoir must drained manually.
47 - 001 - 37
reservoir is drained automatically.
A
Maintenance
Procedure
1. Hold the drain of the water filter
reservoir between two fingers.
2. Push and hold the drain button (A)
until the water filter reservoir is
empty.
38 47 - 001 -
9 Troubleshooting
Problem Possible cause Solution
The tool does not move. The tool is not correctly lubrica-
The tool leaks externally. There is too much lubrication
The tool moves slower than
usual.
The tool moves while the trigger switch is not pulled.
The trigger switch does not
move.
The screws of the gearbox
housing are loose.
Troubleshooting
Make sure that the air lubricator
ted.
The air supply is moist. Make sure that the air supply is
The air motor is defective. Contact your local HYTORC
The gearbox is defective. Contact your local HYTORC
oil in the tool.
Air leaks from the tool. Contact your local HYTORC
The air motor is worn. Contact your local HYTORC
The tool is not correctly lubricated.
Gearbox maintenance is necessary.
The air pressure is too low. Make sure that the air supply
The diameter of the air hose is
smaller than 3/4".
The FRL filter is clogged. Contact your local HYTORC
The low-noise muffler is clogged.
The tool is out of calibration. Contact your local HYTORC
The control valve is dirty. Contact your local HYTORC
The control valve is worn. Contact your local HYTORC
The trigger switch is dirty. Contact your local HYTORC
The screws are not correctly
tightened.
is adjusted to four drops per
60-90 seconds.
dry.
representative.
representative.
Make sure that the air lubricator
is adjusted to four drops per
60-90 seconds.
representative.
representative.
Make sure that the air lubricator
is adjusted to four drops per
60-90 seconds.
Contact your local HYTORC
representative.
pressure is between 6.2 bar (90
psi) and 10 bar (145 psi) at a
maximum air consumption of
1,500 l/min.
Use an air hose with an internal
diameter larger than 3/4".
representative.
Contact your local HYTORC
representative.
representative.
representative.
representative.
representative.
Tighten the screws correctly.
47 - 001 - 39
R
LW
H
Technical data
10 Technical data
10.1 Single Speed
10.1.1 jGun J-.25
Drive
Radius (R) 31.8 mm 1.25"
Length (L) 181.6 mm 7.15"
Height (H) 179.3 mm 7.06"
Width (W) 69.1 mm 2.72"
Weight 3.3 kg 7.2 lbs.
Minimum torque 68 Nm 50 ft.lbs.
Maximum torque 338 Nm 250 ft.lbs.
Rpm 65
3/4"
10.1.2 jGun J-.5
Drive
Radius (R) 31.8 mm 1.25"
Length (L) 204.9 mm 8.07"
Height (H) 185.9 mm 7.32"
Width (W) 69.6 mm 2.74"
Weight 3.3 kg 7.2 lbs.
Minimum torque 183 Nm 135 ft.lbs.
Maximum torque 678 Nm 500 ft.lbs.
Rpm 24
3/4"
40 47 - 001 -
10.1.3 jGun J-1
Drive 3/4"
Radius (R) 31.8 mm 1.25"
Length (L) 224.0 mm 8.82"
Height (H) 179.3 mm 7.06"
Width (W) 69.1 mm 2.72"
Weight 4.0 kg 8.8 lbs.
Minimum torque 407 Nm 300 ft.lbs.
Maximum torque 1,627 Nm 1,200 ft.lbs.
Rpm 6.5
10.1.4 jGun J-2
Technical data
Drive
Radius (R) 33.2 mm 1.31"
Length (L) 265.7 mm 10.46"
Height (H) 201.7 mm 7.94"
Width (W) 89.7 mm 3.53"
Weight 6.6 kg 14.5 lbs.
Minimum torque 712 Nm 525 ft.lbs.
Maximum torque 2,847 Nm 2,100 ft.lbs.
Rpm 5.5
10.1.5 jGun J-3
Drive
Radius (R) 33.2 mm 1.31"
Length (L) 282.2 mm 11.11"
Height (H) 201.7 mm 7.94"
Width (W) 89.7 mm 3.53"
Weight 8.5 kg 18.75 lbs.
Minimum torque 1,119 Nm 825 ft.lbs.
Maximum torque 4,102 Nm 3,025 ft.lbs.
Rpm 4.5
1"
1"
10.1.6 jGun J-5
Drive
Radius (R) 38.1 mm 1.50"
Length (L) 322.1 mm 12.68"
Height (H) 204.0 mm 8.03"
Width (W) 80.0 mm 3.15"
Weight 9.7 kg 21.45 lbs.
Minimum torque 1,560 Nm 1,150 ft.lbs.
Maximum torque 6,847 Nm 5,050 ft.lbs.
Rpm 2.5
47 - 001 - 41
1 1/2"
R
LW
H
Technical data
10.1.7 jGun J-8
Drive 1 1/2"
Radius (R) 38.1 mm 1.50"
Length (L) 353.1 mm 13.90"
Height (H) 214.9 mm 8.46"
Width (W) 107.4 mm 4.23"
Weight 13.75 kg 30.32 lbs.
Minimum torque 2,475 Nm 1,825 ft.lbs.
Maximum torque 10,711 Nm 7,900 ft.lbs.
Rpm 1.5
10.2 Dual Speed
10.2.1 jGun DSP-.5
Drive
Radius (R) 31.8 mm 1.25"
Length (L) 254.7 mm 10.03"
Height (H) 188.0 mm 7.40"
Width (W) 75.9 mm 2.99"
Weight 4.1 kg 9.0 lbs.
Minimum torque 109 Nm 80 ft.lbs.
Maximum torque 521 Nm 385 ft.lbs.
Rundown rpm 420
Final torque rpm 24
42 47 - 001 -
3/4"
10.2.2 jGun DSP-1
Drive 3/4"
Radius (R) 31.8 mm 1.25"
Length (L) 273.3 mm 10.76"
Height (H) 226.6 mm 8.92"
Width (W) 75.9 mm 2.99"
Weight 4.4 kg 9.7 lbs.
Minimum torque 428 Nm 315 ft.lbs.
Maximum torque 1,660 Nm 1,225 ft.lbs.
Rundown rpm 120
Final torque rpm 6.5
10.2.3 jGun DSP-2
Technical data
Drive
Radius (R) 31.8 mm 1.25"
Length (L) 318.0 mm 12.50"
Height (H) 214.0 mm 8.42"
Width (W) 113.8 mm 4.48"
Weight 6.8 kg 15.0 lbs.
Minimum torque 678 Nm 500 ft.lbs.
Maximum torque 2,780 Nm 2,050 ft.lbs.
Rundown rpm 90
Final torque rpm 5
10.2.4 jGun DSP-3
Drive
Radius (R) 46.0 mm 1.81"
Length (L) 316.9 mm 12.48"
Height (H) 186.0 mm 7.34"
Width (W) 81.0 mm 3.19"
Weight 5.4 kg 12.0 lbs.
Minimum torque 1,065 Nm 785 ft.lbs.
Maximum torque 4,406 Nm 3,250 ft.lbs.
Rundown rpm 35
Final torque rpm 2
1"
1"
10.2.5 jGun DSP-5
Drive
Radius (R) 55.1 mm 2.17"
Length (L) 372.1 mm 14.65"
Height (H) 213.9 mm 8.42"
Width (W) 113.8 mm 4.48"
Weight 10.2 kg 22.5 lbs.
Minimum torque 1,593 Nm 1,175 ft.lbs.
47 - 001 - 43
1 1/2"
R
LW
H
Technical data
Maximum torque 7,050 Nm 5,200 ft.lbs.
Rundown rpm 38
Final torque rpm 2.5
10.2.6 jGun DSP-8
Drive 1 1/2"
Radius (R) 62.0 mm 2.44"
Length (L) 390.6 mm 15.38"
Height (H) 214.9 mm 8.46"
Width (W) 115.8 mm 4.56"
Weight 13.4 kg 28.8 lbs.
Minimum torque 2,170 Nm 1,600 ft.lbs.
Maximum torque 11,253 Nm 8,300 ft.lbs.
Rundown rpm 35
Final torque rpm 1.5
10.3 Nut Runner
10.3.1 jGun J-A1-AP-WG
Drive
Radius (R) 38.1 mm 1.50"
Length (L) 284.7 mm 11.21"
Height (H) 195.0 mm 7.70"
Width (W) 86.9 mm 3.42"
Weight 5.4 kg 12.00 lbs.
Minimum torque 346 Nm 255 ft.lbs.
44 47 - 001 -
3/4"
Maximum torque 1457 Nm 1,075 ft.lbs.
Rundown rpm 322
Final torque rpm 17
10.3.2 jGun A1-Z
Drive 3/4"
Radius (R) 50.0 mm 1.98"
Length (L) 303.0 mm 11.92"
Height (H) 241.0 mm 9.47"
Width (W) 84.0 mm 3.29"
Weight 6.9 kg 15.18 lbs.
Minimum torque 407 Nm 300 ft.lbs.
Maximum torque 1627 Nm 1,200 ft.lbs.
Rundown rpm 4000
Final torque rpm 7
Technical data
10.4 Physical conditions
Ambient temperature
Relative humidity 30% - 95%, non-condensing
Maximum altitude 1,000 m (3,200 ft) above sea level
Lighting normal ambient lighting
Note: The tool is not suitable for use in explosive environments.
0 - 45 °C (0 - 113 °F)
10.5 Maximum torque values (male hex sockets)
Maximum torque (Nm)
Hex size (mm) Hex size (inch) Normal Break
14 1/2 476 517
17 5/8 932 1,020
19 3/4 1,612 1,768
22 2,500 2,775
7/8 2,557 2,808
24 2,950 3,600
1 3,822 4,216
27 4,000 4,800
1 1/8 5,440 5,984
32 1 1/4 7,480 8,296
36 1 3/8 9,928 10,880
1 1/2 12,920 14,144
41 1 5/8 16,320 17,952
47 - 001 - 45
Technical data
Maximum torque (Nm)
Hex size (mm) Hex size (inch) Normal Break
46 1 3/4 20,400 22,440
1 7/8 25,160 27,608
50 30,600 33,592
55 43,520 47,736
Maximum torque (ft.lbs.)
Hex size (mm) Hex size (inch) Normal Break
14 1/2 351 382
17 5/8 688 753
19 3/4 1,190 1,305
22 1,845 2,048
7/8 1,887 2,072
24 2,177 2,657
1 2,821 3,111
27 2,952 3,542
1 1/8 4,015 4,416
32 1 1/4 5,520 6,122
36 1 3/8 7,327 8,029
1 1/2 9,535 10,438
41 1 5/8 12,044 13,249
46 1 3/4 15,055 16,561
1 7/8 18,568 20,375
50 22,583 24,791
55 32,118 35,229
1 ft.lbs. = 1.356 Nm
1 Nm = 0.738 ft.lbs.
Note: If the area of the hex drive is smaller
than the square drive, HYTORC will disclaim any liability for broken hex drives or
hex sockets. These male hex sockets are
excluded from warranty claims:
• 1/2” x 17 mm (11/16") and smaller
• 3/4” x 22 mm (7/8”) and smaller
• 1” x 27 mm (1 1/8") and smaller
• 1 1/2” x 46 mm (1 5/6”) and smaller
• 2 1/2” x 70 mm (2 1/2”) and smaller
Extra shear forces and bending forces
caused by an imperfect reaction level
and/or a short reaction distance will lower
the specified torque values in the table.
• Male hex socket
46 47 - 001 -
11 Declaration of Conformity
Declaration of Conformity
(according to Annex II.1.A of the Machinery Directive)
We,
HYTORC BV
Platinawerf 8, 6641 TL Beuningen
The Netherlands
declare under our own responsibility:
We are the manufacturer of the jGun pneumatic socket wrench with optional
accessories.
The jGun pneumatic socket wrench with optional accessories is in conformity with
the provisions of the following directives:
- 2006/42/EC (Machine Directive)
- 98/23/EC (Pressure Equipment Directive)
The following harmonized standards have been applied:
- EN ISO 12100-1:2011
- EN ISO 12100-2:2011
- EN ISO 14121-1:2007
- EN ISO 11148-6:2012
- EN ISO 4414:2010
- EN 61310-2:2008
- EN 61310-3:2008
- ISO 3744:2011
Place: Beuningen (Netherlands)
Date: January 05, 2016
Name: HYTORC
CEO: M. van Kortenhof
Declaration of Conformity
47 - 001 - 47
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