TorcUP ULTRA series, ULTRA UT-3, ULTRA UT-2, ULTRA UT-7, ULTRA UT-11 Operating And Maintenance Instructions Manual
Version 1-2008
September 2008
OPERATION AND MAINTENANCE MANUAL
FOR TorcUP ULTRA UT-2, UT-3, UT-7, UT-11,
SQUARE DRIVE HYDRAULIC TORQUE WRENCHES
UTLRA Series UT-2, UT-3, UT-7, UT-11, Square Drive Hydraulic Torque Wrenches are designed for
installing and removing threaded fasteners requiring precise high torque during bolt makeup and
maximum torque during bolt breakout.
TorcUP Inc. is not responsible for customer modification of tools for applications on which TorcUP Inc.
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
PLACING TOOL IN SERVICE
• 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 gener a t i ng
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
fittings. Make certain there are no cracks, splits
or leaks in the hoses.
The use of other than genuine TorcUP replacement parts may result in safety hazards, decreased tool performance,
and 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 Office or Distributor.
TorcUP Inc.
Printed in U.S.A.
For Technical Support and Information Contact:
1025 Conroy Place, Easton, PA 18040
Phone: (610) 250-5800 Fax: (610) 250-2700
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NOTICE
was not consulted.
WARNING
• Use the quick connect system to attach the hoses to the
tool and pump. Make certain the spring-loaded retaining
rings are fully engaged to prevent the connectors from
disengaging under pressure.
• When connecting hoses that have not been preloade d
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.
USING THE TOOL
• 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. Onl y 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.
NOTICE
TorcUP, Inc.
E-mail: info@torcup.com
.
FAILURE TO OBSERVE THE FOLLOWING WARNING COULD RESULT IN INJURY
WARNING
USING THE TOOL
*Keep hands, loose clothing and long hair away from the
reaction arm and working area during operation. Do not
attempt to support the tool with your hands 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 fit the
bolt or nut and function without tilting the tool off the axis
of the bolt.
*This tool is not designed for working in explosive atmo-
spheres
*This tool is not insulated against electric shock. When
using this tool with a pump having an electrical power
source or circuits, follow the pump instructions for proper
grounding.
* Use only impact sockets and accessories that are appro-
priately rated for the output of the tool.
*Always use retaining pin and ring to engage the socket
to the square drive.
*Inspect sockets for signs of over use before utilizing with
tool.
CONNECTING THE TOOL
1. Attach the twin line hose to the swivel inlets of the
Square Drive Torque Wrench using the spring - loaded
quick connects ends. After making certain that they are
fully engaged, thread the safety rings tightly against the
spring–loaded retainer rings.
2. Connect the opposite ends of the hose to the Pump in the
same manner.
ADJUSTMENTS
SETTING THE SQUARE DRIVE FOR ROTATION
The position of the Square Drive when looking toward the
Shroud will determine if the tool is set to tighten or loosen
the nut. When the Square Drive extends to the left when
looking at the Shroud with the inlets away from you, the
tool is set to loosen the nut. When the Square
Drive extends to the right, the tool is set to tighten the nut. To
change the direction of rotation forModels UT-2 UT-3, UT-7
and UT-11simply push the Square Drive into the housing
until the Drive projects out the opposite side of the tool.
SETTING THE TORQUE
After determining the desired torque, use the torque con-ver-
sion chart on the Shroud or the torque conversion charts on
page 5 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. Con’t...
PLACING THE TOOL IN SERVICE
PLACING THE TOOL IN SERVICE
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 confirm that the
desired pressure setting has been obtained.
SETTING THE REACTION ARM
The function of a reaction device is to hold the tool in
position against the forces generated to tighten or loosen
bolts or nuts. Hydraulic wrenches generate tremendous
force.
An improperly positioned reaction arm may
result in operator injury or damaged tooling.
Square Drive Hydraulic Wrench
Reaction Points (Dwg. 01)
Make sure the Reaction Arm is positioned correctly.
(Refer to Drawing 01).
The Reaction Arm can be positioned numerous places
within a 360
correctly positioned, it must be set within a 90
of that circle. That quadrant is the area located between
the protruding Square Drive and the bottom of the
Housing away from the Swivel Inlets. It will always be
toward the lower half of the Housing and on one side of
the Housing when tightening and the other side when
loosening.
OPERATING THE WRENCH
The position of the Square Drive relative to the Shroud
determines whether the action will tighten or loosen the
nut. (Refer to Dwg. 02 for application examples).
The power stroke of the Piston Assembly will always
turn the Square Drive toward the Shroud.
WARNING
REACTION
REACTION
CONTACT
CONTACT
POINTS
POINTS
REACTION
REACTION
CONTACT
CONTACT
POINTS
POINTS
O
circle. However, for the Arm to be
O
quadrant
WRENCH POSITIONS
Square Drive Position for Loosening and
Tightening (Dwg. 02)
FOR LOOSENING
FOR LOOSENING
FOR LOOSENING
SHROUD
SHROUD
SHROUD
FOR TIGHTENING
FOR TIGHTENING
FOR TIGHTENING
SHROUD
SHROUD
SHROUD
1. Place the Square Driver in the socket and the socket
on the nut. Make certain the Square Driver and socket
are the correct size for the nut and that the Driver fully
engages the socket and that the socket is pinned to the
Driver with retaining ring and pin.
2. Position the reaction arm or surface against an
adjacent nut, flange or solid system component. Make
certain that there is clearance for the hoses, swivels,
inlets and End Plug. DO NOT allow the tool to react
against the hoses, swivels, inlets or End Plug.
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
4. When the wrench is started, the reaction surface of the
wrench or Reaction Arm 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. Once the nut stops rotating, cycle the tool one last
time to achieve total torque.
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