TORQUE GUN THRILL jGUN Operational And Spare Parts Manual

THANK YOU FOR PURCHASING THIS REVOLUTIONARY TORQUE/TENSION SYSTEM

PLEASE CALL YOUR HYTORC REPRESENTATIVE TO SCHEDULE A FREE TRAINING THAT WILL

HELP YOU GET THE MOST OUT OF THIS ADVANCED BOLTING SYSTEM.

OPERATING CD: Please show the enclosed CD to your staff before each tool use to familiarize them

with the tools.

FREE SAFETY TRAINING: To ensure safe operation, please request the FREE Safety Training

before use by calling your local HYTORC Representative 1-800-367-4986 or www.hytorc.com.
We recommend safety training every 6 months. These trainings are free of charge. Just call us.

PLEASE READ THE SAFETY INSTRUCTIONS HEREIN.

SYSTEM INSPECTION: Before any use, please inspect the entire tool system, including hoses, gauge,

sockets and backup wrenches. Do not use kinked hoses, oversized or heavily worn sockets, backup
wrenches, damaged tools, pumps, connectors, or gauges. Connect system to operate from a safe
distance. Ensure fasteners are in good shape. Check out tool functioning with drive or hex ratchet
turning in one direction only and check out gauge from a safe distance that needle is on zero at
no pressure and at 10,000 psi at high pressure. Keep high pressure on and check system visu­ally for leaks. Please keep in mind that hydraulic tools are very strong and work at high pressure.

HANDS-FREE BOLTING: The tool you have purchased permits hands-free operation from a safe

distance in conjunction with a HYTORC Washer™. We recommend the use of a HYTORC Washer™

to avoid nger-pinching, over-crowded sites and to ensure hands-free bolting at least on all vertical

and inverted applications, while eliminating improvisation and the use of reaction members or
backup wrenches. Otherwise, set up the tool in a way that it does not have to be held by hand.
For more information, please contact us at 1-800-367-4986 or www.hytorc.com.

HANDS-FREE WASHER APPLICATION: Make sure the drive and the tool are locked on securely.

FREE ANNUAL TOOL INSPECTION: With the purchase of HYTORC, you have the right to a FREE

annual tool inspection which includes free seals, springs, connectors, and free lubrication. In case of
damaged or worn parts, the rst inspection within 12 months of purchase is free of charge. There­after, you will be informed of any cost prior to replacement. Any part replaced and charged by us
will be sent to you for your inspection upon request when P.O. is issued.

FREE LOANER TOOLS: In case of tool failure during the warranty or rental period, please contact

your local HYTORC Agent for a free loaner tool - 24/7.

STAY SAFE

HOSE REPLACEMENT: We recommend replacing hydraulic hoses and oil every (3) three months.

PLEASE WEAR REQUIRED SAFETY ATTIRE and use common sense during operation.

HELP: If you require any further assistance, please call your local HYTORC Representative or

1-800-FOR-HYTORC (1-800-367-4986), on the web at www.hytorc.com - 24/7! It’s live!

PLEASE REVIEW THESE SAFETY

TIPS BEFORE EVERY TOOL USE

No. Safety 1-2-1009

THRILL™

OPERATIONAL AND SPARE PARTS MANUAL

CONTENTS

Warranty 4
jGun Overview 5
jGun Safety 6
jGun Setup and use 7
THRILL Gun Overview 9
THRILL Gun Specifications 10
Torque/Speed Settings 11

High Speed Operation (Impact) 11
Maximum Torque Operation 12
Switching Settings 13
Typical Usage 14
FRL (Filter, Regulator, Lubricator) Overview 16
FRL Setup and Use 18

FIGURES

Figure 1: THRILL Gun with Socket 9
Figure 2: THRILL Gun Dimensions 10
Figure 3: Torque Operation Settings - High Speed (Impact)/Maximum Torque 11
Figure 4: Holding the THRILL in the High Speed (Impact) Setting 11
Figure 5: Safety Position for THRILL Gun in Maximum Torque Setting 12
Figure 6: Switching from Maximum Torque to High Speed (Impact) 13
Figure 7: High Speed (Impact) Rundown 15
Figure 8: Maximum Torque Demonstration 15
Figure 9: FRL Unit (Shown without silencer) 16
Figure 10: FRL Unit 19
Figure 11: Detaching FRL Reservoir 19
Figure 12: FRL Unit, Lubricator 2/3rds Full of Oil 20
Figure 13: Adjusting FRL Regulator 21
Figure 14: Adjusting FRL Oil Flow 22

TABLES

Table 1: Bolt Torque Specications 8
Table 2: THRILL Gun Specifications 9

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3

WARRANTY

The jGun 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 from repairs
made or attempted by other than 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 prots.
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 specic 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.

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4

jGUN OVERVIEW

The jGun pneumatic torque wrench is designed to safely and accurately deliver up to 5,200 ft-lbs of
torque onto a fastener. This is accomplished using a patented planetary gearbox torque multiplier sys­tem and an appropriate reaction arm or HYTORC Washer™ and HYTORC Nut™. The torque multiplier
produces torque ratios of up to 1450:1 while the reaction arm or washer is used to absorb the high coun­ter rotational force produced as the nal torque value is reached. At nal torque value, the jGun safely
stalls out, leaving the fastener tightened to specication.

Unlike impact wrenches, the jGun never transmits working torque to the operator. The torque is applied
between the fastener and the reaction surface.

This manual provides information for both the standard THRILL jGun.

BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

5

jGUN SAFETY

Only qualied personnel who have thoroughly read this document may operate this tool. Failure to safely
operate this tool may result in serious injury or death.

• Inspect all jGun components as they are removed from the shipping container. If damage is
found to any component, contact your 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.

• jGun maintenance and repair must be performed by a qualied pneumatic technician.

• Modifying a jGun or jGun accessory is dangerous and invalidates the warranty.

• Inspect the tool before each use. Replace any obviously worn or damaged parts.

• When not in use, store the jGun and jGun 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 jGun including
gloves, safety goggles, hearing protection, hard hat, and safety shoes.

Air Supply Requirements

• The air supply line must be ½-inch minimum diameter to allow adequate air ow to the jGun.

• The air supply must provide a minimum of 90 psi at 30 cfm.

• Ensure that air line ttings are tight and leak free. Do not over tighten air line ttings.

• Always use the Filter Regulator Lubricator (FRL) Unit provided with the jGun. Never use a substi-

tute oiler and regulator.

Set the air pressure at the FRL while the tool is running as described in FRL Setup and Use.

• Open the air supply connected to the FRL unit and run the jGun while setting the pressure on the
regulator gauge.

• Set the air pressure to the PSI needed to achieve desired torque shown on the provided pres­sure/torque conversion chart, also shown in Pressure / Torque Conversion Charts.

NOTE

BREAKTHROUGH PRODUCTS FOR INDUSTRIAL BOLTING

6

jGUN SETUP AND USE

Proper setup and use of the jGun before and during installation ensures accurate results and safe op­eration. The FRL Unit provided with the jGun must be used with the hose provided to ensure the tool’s
durability. See the FRL Unit Overview section below for more information.

Setting a Torque Value

1. Determine the torque value for the fastener to be tightened, as shown in the Bolt Torque Speci­cations table on page 8.

2. Determine the air pressure needed to achieve the desired torque by consulting the Pressure/
Torque Conversion Chart provided with each tool.

3. Open the air supply connected to the FRL unit and run the torque wrench while setting the pres­sure on the gauge.

NOTE

The torque wrench must be running while the pressure is being set. When the torque
wrench is stopped, the gauge displays a slightly higher pressure than was set with the
jGun running. This is normal, proper torque is delivered under working load.

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7

Table 1 - Bolt Torque Specications

SAE1 SAE2

30,000PSI

ASTM 193 Grade

B7 Bolt

Gr. 7 A/F Heavy Hex

Nut

Foot Pounds Estimated Load

1 inch 7/8 inch 1-7/16 inches 300 18,150 lbf

1-1/8 inches 1 inch 1-5/8 inches 425 23,690 lbf

1-1/4 inches 600 29,955 lbf

1-3/8 inches 1-1/8 inches 1-3/16 inches 700 36,990 lbf

1-1/4 inches 2 inches 800 46,776 lbf

1-1/2 inches 900 44,760 lbf

1-5/8 inches 1-3/8 inches 2-3/16 inches 1,250 53,400 lbf

1-1/2 inches 2-3/8 inches 1,500 64617 lbf

1-3/4 inches 1,600 62,400 lbf

1-7/8 inches 1,800 72,300 lbs

1-5/8 inches 2-9/16 inches 2,000 76,540 lbs

2 inches 2,200 83,100 lbs

1-3/4 inches 2-3/4 inches 2,600 89,440 lbs

2-1/4 inches 3,000 106,800 lbs

1-7/8 inches 2-15/16 inches 3,700 110,680 lbs

2-1/2 inches 2 inches 3-1/8 inches 4,000 133,200 lbs

2-3/4 inches 5,100 162,900 lbs

The Data Above is based on bolts lubricated to manufacturer’s specifications.
Due to a variation in friction, we recommend in extreme cases to check with the
bolt manufacturer, as the chart represents a guideline only.

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