TorcUP TXU-2, TXU-4, TXU-8, TXU-16 User Manual

TXU Series

OPERA TION AND MAINTENANCE

MANUAL

TXU Series Uniswivel Low Prole

Hydraulic Torque Wrenches

MODELS TXU-2, TXU-4, TXU-8 and TXU-16

1025 Conroy Place, Easton, PA. 18040 U.S.A.

Phone: [phone]

Fax: [phone]

Toll Free: 1-888-TORCUP-1

Email: [e-mail]

Website: www.torcup.com

Operational and Maintenance Manual for TorcUP

TXU-2, TXU-4, TXU-8, and TXU-16

Uniswivel Low Prole Hydraulic Torque Wrenches

Version 2: 2016 September

NOTICE

Series TXU-2, TXU-4, TXU-8, and TXU-16 Low Prole Hydraulic Torque Wrenches are designed for

installing and removing threaded fasteners having minimal wrench clearance and requiring precise high

torque during bolt makeup and maximum torque for bolt breakout.

TorcUP Inc. is not responsible for customer modication of tools for applications on

which TorcUP Inc. was not consulted.

WARNING

IMPORTANT SAFETY INFORMATION ENCLOSED.

READ THIS MANUAL BEFORE OPERATING TOOL.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS

MANUAL INTO THE HANDS OF THE OPERATOR.

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.

USING THE TOOL

• Always operate, inspect and maintain this tool in accordance with American National Standards

Safety Code for Hydraulic Rams and Jacks (ANSI B30.1).

• This tool will function using an air or electric powered hydraulic pump. Adhere to the pump safety

requirements and follow instructions when connecting the pump to the tool.

• Use only equipment rated for the same pressure and torque.

• Use only a hydraulic pump capable of generating 10,000 psi (681 bar) maximum pressure with this
tool.

• Use only twin line hydraulic hose rated for 10,000 psi (681 bar) pressure with this tool.

• Do not interchange the male and female swivel inlets on the tool or the connections on one end of

the hose. Reversing the inlets will reverse the power stroke cycle and may damage the tool.

• Do not use damaged, frayed or deteriorated hoses and ttings. Make certain there are no cracks,

splits or leaks in the hoses.

• Use the quick connect system to attach the hoses to the tool and pump.

• When connecting hoses that have not been preloaded with hydraulic oil, make certain the pump

reservoir is not drained of oil during start-up.

• Do not remove any labels. Replace any damaged label.

• Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing

serious injury. If oil is injected under the skin, see a doctor immediately.

• Never pressurize uncoupled couplers. Only use hydraulic equipment in a coupled system.

• Always wear eye protection when operating or performing maintenance on this tool.

• Always wear head and hand protection and protective clothing when operating this tool.

The use of other than genuine TorcUP replacement parts may result in safety

hazards, decreased tool performance, increased maintenance, and may invalidate

all warranties. Repairs should be made only by authorized personnel. Consult

your nearest TorcUP Authorized Service Center.

Refer All Communications to the Nearest TorcUP Ofce or Distributor.

For Technical Support & Information Contact:

TorcUP Inc.

1025 Conroy Place, Easton, PA 18040 USA

Phone: [phone] Fax:[phone]

email: [e-mail]

1

WARNING

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY

Do NOT Exceed Maximum Pressure. See Torque Chart with Tool. Damage May Occur.

Do not use damaged,

frayed or deteriorated
hydraulic hoses

and ttings.

Always wear ear
protection

when operating

this tool.

Keep body stance

balanced and rm.

Do not overreach

when operating

this tool.

Always wear eye
protection

when operating or
performing

maintenance
on this tool.

Do not carry
the tool
by the hose.

The Torque Reaction Arm must be

positioned against a positive stop.

Do not use the arm as a dead

handle. Take all precautions to

make certain the operator’s hand

cannot be pinched between the
arm and a solid object.

USING THE TOOL

• Keep hands, loose clothing and long hair away from the reaction arm and working area during operation.

• This tool will exert a strong reaction force. Use proper mechanical support and correct reaction arm

positioning to control these forces. Do not position the reaction arm so that it tilts the tool off the axis of the

bolt and never use the swivel inlets as a reaction stop.

• Avoid sharp bends and kinks that will cause severe back-up pressure in hoses and lead to premature hose
failure.

• Use accessories recommended by TorcUP.

• Use only impact sockets and accessories. Do not use hand (chrome) sockets or accessories.

• Use only sockets and accessories that correctly t the bolt or nut and function without tilting the tool off the
axis of the bolt.

• This tool is not insulated against electric shock.

• This equipment must not be operated or serviced unless the operator read the operating instructions and
fully understands the purpose, consequences and procedure of each step.

• When operating a larger tool (TXU-16) above waist height, employ a secondary means of support for safety

purposes. A tool sling or chains may be used. Consult your safety department for further suggestions.

Depending on the working environment your local health and safety regulations may require
you wear protective gear (i.e. safety shoes, hard hat, gloves, coveralls, etc.). In case external
forces are exerted on the equipment, non-compliance with these regulations may result in
injury. EAR PROTECTION MUST BE WORN WHEN OPERATING THIS TOOL.

2

PLACING THE TOOL IN SERVICE

CONNECTING THE TOOL

1. Attach the twin line hose to the swivel

inlets of the low prole drive cylinder
using the spring–loaded quick connect

ends.

2. Connect the opposite ends of the hose
to the pump in the same manner.

3. Push the link retaining pin out of the
low prole drive cylinder.

4. Mate the selected ratchet link to the

cylinder by inserting the end of the

cylinder opposite the swivel inlets
between the side plates of the ratchet

link. (Refer to Dwg. 1)

5. Align the holes for the link retaining pin and insert the pin through the side plates and cylinder to keep

the units joined together.

Dwg. 1

SETTING THE TORQUE

After determining the desired torque, use the torque conversion charts on pages 6 to 13 to determine the

pressure that is necessary to achieve that torque.

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

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

3. Adjust the pressure by loosening the wing nut that locks the pressure adjustment thumbscrew.Rotate
the thumbscrew clockwise to increase the pressure and counterclockwise to decrease the pressure.
When decreasing pressure, always lower the pressure below the desired point and then bring the
gauge back up to the desired pressure.

4. When the desired pressure is reached, retighten the wing nut and cycle the tool again to conrm that

the desired pressure setting has been obtained.

OPERATING THE WRENCH

The position of the tool relative to the nut determines

whether the action will tighten or loosen the nut.
(Refer to Dwg. 2 for application examples). The power
stroke of the piston assembly will always turn the ratchet

hex toward the shroud.

1. Place the ratchet hex on the nut. Make certain it is the

correct size for the nut and that it fully engages the nut.

2. Position the reaction surface against an adjacent

nut, ange or solid system component. Make certain

that there is clearance for the hoses, swivels and inlets.

DO NOT allow the tool to react against the hoses or

swivels.

Wrench Positions Dwg. 2

3

PLACING THE TOOL IN SERVICE

3. After having turned the pump on and presetting the pressure for the correct torque, depress

the remote control button to advance the piston assembly. If the notch in the piston rod did not

engage the retract pin in the ratchet link when the link was joined to the housing, it will engage the
pin automatically during the rst advance stroke.

4. When the link is connected to the cylinder and the wrench is started, the reaction surface of the

wrench will move against the contact point and the nut will begin to turn.

5. When the nut is no longer turning and the pump gauge reaches the preset pressure, release the
remote control button. The piston rod will retract when the button is released and under normal

conditions, an audible “click” will be heard as the tool resets itself.

6. Continue to cycle the tool until it “stalls” and the preset psi/torque has been attained.

7. Cycle the tool one additional time to ensure full torque.

LUBRICATION

MARINE MOLY GREASE

Lubrication frequency is dependent on factors known only to the user. The amount of contaminants in
the work area is one factor. Tools used in a clean room environment will obviously require less service

than a tool used out-doors and dropped in loose dirt or sand. Marine Moly Grease is formulated not to
wash out of the tool in areas where lubrication is critical. Whenever lubrication is required, lubricate as
follows:

1. Separate the low prole cylinder from the ratchet link if they are joined.

2. After wiping off the old grease, apply a daub of Marine Moly Grease to the hooking notch in the

piston rod, and wipe a lm of Marine Moly Grease onto the sides and faces of the two sliders.

3. Disassemble the ratchet link as instructed in the Maintenance Section and wash the components
in a suitable cleaning solution in a well ventilated area.

4. Dry the components, then wipe a lm of Marine Moly Grease onto the wear surface of both side
plate sleeves and the hubs of the ratchet.

5. Spread a light lm of Marine Moly Grease onto the inner faces of both side plates, covering the

area where the drive plate and drive segment travel. DO NOT pack the teeth of the drive segment
or ratchet with lube. It can prevent the teeth from engaging properly.

6. Reassemble the ratchet link as instructed in the Maintenance Section.

4

TXU Series Uni-Swivel Wrench Technical & Dimensional Data

Model Number TXU-2 TXU-4 TXU-8 TXU-16

Min. Torque (ft/lbs) 192 395 830 1560
Max. Torque (ft/lbs) 1928 3950 8630 16600
Min. Torque (nm) 260 535 1125 2115
Max. Torque (nm) 2614 5355 11699 22503

Output Accuracy +/-3% +/-3% +/-3% +/-3%
Repeatability 100% 100% 100% 100%
Duty Cycle 100% 100% 100% 100%

Cylinder Weight (lbs/kg) 4.0/1.8 6.9/3.1 12.5/5.7 16/7.3

Link Weight

Length 1 (in/mm) 6.45/163.8 7.87/199.9 10.81/258.6 12.93/328.4
Length 2 (in/mm) 5.99/152.4 6.58/167.1 7.34/186.4 8.20/208.2
Width 1 (in/mm) 1.25/31.8 1.63/41.4 2.05/52.1 2.50/63.5
Width 2 (in/mm) 2.19/55.6 2.26/57.4 2.26/57.4 2.26/57.4
Radius (in/mm) 0.36/9.1 0.46/11.7 0.54/13.7 0.65/16.5
Height 1 (in/mm) 3.39/86.3 4.93/125.2 6.18/157 7.58/192.5
Height 2 (in/mm) 1.11/28.2 1.30/33.0 1.30/33.0 1.30/33.0

(lbs) 2.4-3.5 5.4-7.6 11.9-14.5 21.0-28.0
(kg) 1.0-1.5 2.4-3.4 5.5-6.5 9.5-13.0

5

6

7

8

9