Operating Instructions Hi-force: Series Twp

Transcript

TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- 1398 Date: 30/03/14 OPERATING INSTRUCTIONS Hi-FORCE: SERIES TWP-S and TWP-D Pneumatic Torque Wrench These instructions are issued to ensure safe operation of the tool by the intended Operator To ensure maximum safety a copy of these instructions should accompany the tool at all times. Ensure these instructions are read and fully understood by the operator before use of the tool. Page 1 of 16 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- Contents: 1.0 1.1 1.2 1.3 1.4 2.0 3.0 3.1 3.2 3.3 3.4 3.5 4.0 5.0 5.1 5.2 5.3 Safety.................................................................................3 Operating Parameters........................................................4 Emissions...........................................................................4 Risk Assessment................................................................4 Operator.............................................................................6 Technical Data...................................................................6 Tool Operation...................................................................6 Tool Set-Up........................................................................6 Setting the Torque..............................................................7 Tightening and Loosening Bolts........................................7 TWP-D Operation..............................................................8 Important Technical Notes................................................9 Maintenance and Repair...................................................10 General Tool Arrangements.............................................11 General Arrangement TWP-S..........................................11 General Arrangement TWP-D.........................................12 General Arrangement Air Control Unit...........................13 Page 2 of 16 1398 Date: 30/03/14 TDS:- 1398 OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- Date: 30/03/14 1.0 SAFETY Please carefully read all safety instructions, in order to ensure the safest use and longest service life of the equipment supplied. Improper handling, misuse or operation by unqualified personnel will cause risks for The operator's health and life The machine and other objects KEEP these operating instructions and other applicable Hi-Force manuals in a safe place, and ensure they are available for all personnel that install, use or maintain the equipment. Work Area. Ensure the work area is kept clean and tidy. Identify the risk area in which the tool is to be used. Do not use the power tool in an area that is subject to the risk of explosion, in which flammable liquids, gases or dusts are present. Ensure that no unauthorised personnel are within the working/risk area when the equipment is in use. Never leave the working/risk area with the equipment under load. Be aware: Distraction can cause you to lose control of the power tool. Personal Safety. Before commencing work with this equipment, the operator should wear all the personal protective equipment recommended by his/her Company. Also we recommend that non-slip work gloves, ear defenders and safety glasses/visor are worn at all times. Before commencing work the tool should be inspected to ensure:- All moving parts are in the correct working order and are not jammed. - No parts of the tool are broken, badly worn or damaged. - IF IN DOUBT DO NOT USE THE TOOL. Do not use the power tool if you are tired or under the influence of drugs, alcohol or medicines. Inattention when using power tools can lead to serious injury. Do not overestimate your capabilities. Ensure when operating the tool you have a secure stance and that you are evenly balanced. This will allow you to control the power tool better in all situations. Do not wear loose clothing or jewellery. Keep hair, clothing and gloves away from moving parts, as these can become entangled in the moving parts of the power tool. Torque wrenches can be dangerous if used by inexperienced or untrained persons. IF IN DOUBT ASK. Page 3 of 16 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- 1398 Date: 30/03/14 1.1 OPERATING PARAMETERS The Hi-Force Pneumatic Torque Wrench is a hand-operated power tool and must be used exclusively for tightening and unscrewing bolted connections. Never combine the wrench with other tools, such as impact screw drivers or drill. The minimum and maximum torques can be taken from the table corresponding to the torque multiplier and the corresponding setting value must be selected. The torque wrench must be used only with the reaction arms supplied as standard by Hi-Force. Consult Hi-Force, before modifying any support arm, as an uncontrolled operating state (overturning moment) can occur, and lead to the risk of accidents. Any modification to the tool or associated parts without prior written permission from Hi-Force, will be deemed as improper use and all warranty and guarantees on the tool are declared invalid. Use of the tool for any applications other than its intended purpose is deemed to be improper use and warranty will be void. Any unauthorized conversions or modifications of the device are prohibited on safety grounds. All operating and maintenance provisions contained within this operating manual must be complied with. 1.2 EMISSIONS The continuous sound pressure level according to DIN 45635 is 84 dB(A). The vibration is below 2.5 m/s2. 1.3 RISK ASSESSMENT Incorrect use poses the risk of crushing, shearing and serious damage to the torque wrench. Risk of crushing and shearing A jam and shear risk is possible between support arm and abutment (fig. 1+2). The support arm must find a close rest! Fig: 1 Fig: 2 Page 4 of 16 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- 1398 Date: 30/03/14 Risk of tool breakage. Incorrectly applied support arms can fracture (Fig: 3). The support arms should always be applied in opposition to the direction of rotation of the torque wrench. Fig: 3 The risk of overturning moment, by extension of the impact socket, modification of the support arm or reverse fitting of the support arm. The impact socket can fracture and the torque wrench can fail.(Fig:4). Fig: 4 Other hazards A risk of crushing between the pistol-grip and surrounding components. The pistol-grip and /or driving unit are able to rotate. The impact socket and the support arm can become detached if they are not correctly fixed in position. Always lock the impact socket and the support arm, with the locking pin and the rubber collar (fig. 6). Only use impact sockets which conform to DIN 3129 (Sockets) power torque wrenches. Keep the hose of compressed air supply away from the support arm! If there is a cut in the supply of the compressed air, put the wrench safely away. After return of the air supply, loosen the last bolt again and repeat the tightening procedure. The exhaust air of the pneumatic wrench can contain oil! Page 5 of 16 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- 1398 Date: 30/03/14 Direct inhalation could be noxious! Dose the oiler according to the operating instructions. Cut the supply of compressed air, before working on the wrench. Do not disconnect the air supply with the tool working at full operating pressure. 1.4 OPERATOR Minimum age: 18 years The operator must carefully read and understand the operating manual before using the torque wrench. The operator should always act responsibly in their work area and with regard to other persons in the vicinity. 2.0 TECHNICAL DATA Consumption of compressed air: 20 l/s at 6.3 bar Nominal capacity: 0.85 KW Min. and max. torque values are recorded in the attached table. 3.0 OPERATION The wrench should only be put into operation using the air control unit with pressure reduction valve, oiler, filter and water trap. 3.1 TOOL SET-UP Connect the air control unit (30) by a hose of min. NW 13 (35) to the compressed air supply. The hose (39) from the air control unit (30) to the wrench is 4m long and is permanently installed on the control unit (30). The length of the hose (39) may not be altered. Put the support arm (13) onto the spline (11) of the wrench. Then put the impact socket (14) on to the square drive (12). Fix the impact socket (14) and support arm (13) with locking pin (15) and rubber collar (16), see fig. 6. Fig:6. Page 6 of 16 TDS:- 1398 OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- Date: 30/03/14 Put the wrench onto the bolted connection set with the pre-selected torque (see TORQUE SETTING). For the tightening procedure move the support arm (13) against the abutment. For the loosening procedure turn the support (13) slowly towards the abutment by starting the motor. If necessary start motor at intervals! Make sure the support arm has a tight rest against the abutment. The reaction torque must be absorbed by the support arm at the level of the socket. A T T E N T I O N! The support arms will always move for abutment against the direction of rotation of the wrench. Press the trigger (4) on the pistol grip (1) according to the direction of rotation required and hold it depressed until the preselected torque is reached. When the torque is reached, the wrench will come to a standstill. Then run the wrench briefly in the opposite direction, so that the support arm (3) is removed from the abutment. The wrench can now be moved onto the next bolted connection and tightened as described above. 3.2 SETTING THE TORQUE Read off the required torque from the chart (6) fixed to the motor housing and set the necessary air pressure on the pressure gauge (37) by means of the pressure reduction valve (40) while the wrench is running under no-load conditions (dynamic pressure). Between the numbers (e.g. 3 and 4) the torque can be adjusted continuously (inter-polation). The wrench should only be operated using the air control unit (30) with water trap (36), oiler (38) and hose (39) from Hi-Force, this is necessary in order to guarantee the precision of the torque values. The precision of the torque values is only guaranteed, if the torque wrench is used with the original HiForce air control unit. Oiler setting: 1 drop/20 seconds. Oil type: HL 25 DIN 51524 - ISO VG32. The exhaust pipe (34) of the pneumatic motor must always be slightly oiled. Non-observance of this will result in loss of capacity, malfunction and fluctuations in torque. 3.3 TIGHTENING AND UNSCREWING BOLTS Tightening bolts Put the wrench onto the bolted connection set with the pre-selected torque (see TORQUE SETTING). For a tightening procedure move the support arm (13) to the abutment. For a loosening procedure turn the support arm (13) slowly towards the abutment by starting the motor. If necessary start motor at intervals! Make sure the support arm has a tight rest against the abutment. The reaction moment must be absorbed by the support arm at the level of the socket. The support arms will always move for abutment, against the direction of rotation of the wrench. Page 7 of 16 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- 1398 Date: 30/03/14 Keep the toggle switch (4) on the pistol-grip (1) pressed down until the pre-set torque is reached. When the required torque is reached, the motor cuts out automatically. Then change the direction of rotation at the right / left switch (5), press again shortly the on / off switch (4), so that the support arm (13) is removed from the abutment. Now choose again the required direction of rotation, put the wrench onto the next bolted connection and tighten the bolt as the procedure described above. Unscrewing bolts Select the required direction of rotation, using the reversing switch (5) above the on/off switch (4) on the pistol grip (1). If the torque wrench switches off, the torque adjuster setting must be set higher or the higher speed must be selected. 3.4 OPERATION OF THE TWP-D The TWP-D has a 2-speed planetary gear system to facilitate easy switching between rapid speed and power operation 1 = Power speed 2 = Rapid speed NOTE: Only shift the gears when stationary! If the gears are shifted during the bolting operation it can damage the wrench. Rapid speed: Turning in the screw at a high speed of up to 300 rpm. Power speed: Tightening the screw to the exact torque. Device is only calibrated in force(Power) operation! Torque indications in the value table (6) refer to force(Power) operation! Page 8 of 16 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- 1398 Date: 30/03/14 Tightening Screws with the TWP-D Place wrench on the screw connection set with the pre-selected torque (see torque settings) and turn the gear switch (41) to rapid speed (2) until it engages. With the screw connection still loose (tightening), press the toggle switch (4 a) at the wrench carefully until the support arm (13) is aligned with the abutment. Ensure secure placement of the support arm. The reaction torque must be absorbed by the support arm at the height of the impact socket (see fig. 4). Then the toggle switch (4 a) can be pressed in all the way and the screw can be tightened quickly. When the screw connection is tightened to the snugging torque, the gear is switched to power speed (1). Press the toggle switch (4 a) at the pistol handle (1) according to the rotational direction and hold it until the pre-selected torque is achieved. When the selected torque is reached, the device switches off automatically. Then press the toggle switch in the other direction for a moment until the support arm (13) no longer presses against the abatement. Loosening screws with the TWP-D Press and hold the toggle switch (4 b) on the pistol grip (1) according to the rotational direction. When the wrench switches itself off, increase the torque value. Generally, firmly tightened screws should be loosened slightly in power speed (1) and then be fully removed in rapid speed (2). 3.5 IMPORTANT TECHNICAL NOTES In order to achieve constant and accurate repetition of the cut-off points, the bolt must be tightened in one operation without interrupting the procedure from the motor start until the wrench cuts off. Before increasing the torque, the rated speed must be reached. The speed when running idle is in accordance with the selected torque (dynamic air pressure ATTENTION! If the tightening procedure is stopped too soon, this bolt must be loosened again. Then repeat the tightening procedure! A bolt which has already been tightened to the required torque must not be tightened again with the same torque: This will lead to excess torque being applied. A precise repetition of the cut-off points requires constant monitoring of the air pressure and flow. Fluctuations in air pressure and/or unstable air supply can result in impermissible fluctuations in the tightening torque! At constant pressure and flow the accuracy of repetition for the cut-off points lies within a tolerance of +/5%. The calibrated torque values at the different settings are for a bolt with a short length of grip. Bolted connections of other types can result in a different torque. After the gears have been run in (approx. 1000 to 2000 bolts) and thereafter once a year, it is necessary to check and possibly re-calibrate the torques. Page 9 of 16 TDS:- 1398 OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- Date: 30/03/14 After using the wrench, store it at a dry and clean place! In general - when making bolted connections - observe instructions of the manufacturer or the prescriptions of the engineering in the first place. 4.0 MAINTENANCE AND REPAIR The gear parts of the wrench are maintenance-free. All repairs must be made by the manufacturer or its authorized service workshop, as - after the exchange of parts - the accuracy of the torque values must be checked and the wrench must be recalibrated. Use only genuine Hi-Force accessories and genuine Hi-Force spare parts. Hi-Force is not responsible for any personal injury or machine damage that occur due to the use of nongenuine Hi-Force accessories and spare parts or repairs carried out by unauthorized service workshops. Page 10 of 16 TDS:- 1398 OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- 5.0 GENERAL TOOL ARRANGEMENTS 5.1 GENERAL ARRANGEMENT – TWP-S Date: 30/03/14 1 34 6 4a 4b 11 13 12 14 1. 4a. 4b. 6. 11. Pistol Grip Toggle switch right Toggle switch left Torque Setting Spline 12. Square Drive 13. Reaction/ Support Arm 14. Socket (output force) 34. Air Inlet Page 11 of 16 TDS:- 1398 OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- Date: 30/03/14 GENERAL ARRANGEMENT – TWP-D 5.2 1 34 6 4a 41 4b 11 13 12 14 1 4a. 4b. 6. 11. Pistol Grip Toggle switch right Toggle switch left Torque Setting Spline 12. Square Drive 13. Reaction/ Support Arm 14. Socket (output force) 34. Air Inlet 41. Gear Switch Page 12 of 16 TDS:- 1398 OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- 5.3 M.Davies 1 Approved by:- Date: 30/03/14 GENERAL ARRANGEMENT – AIR CONTROL UNIT. 40 35 37 38 36 30 39 30: Air Control Unit Complete 35: Air Supply 36: Water Trap 37: Pressure Gauge 38: Oiler 39: Hose 40: Pressure Reduction Valve Page 13 of 16 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- NOTES: Page 14 of 16 1398 Date: 30/03/14 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- NOTES: Page 15 of 16 1398 Date: 30/03/14 TDS:- OPERATING INSTRUCTIONS Pneumatic Torque Wrench. Series: TWP-S & TWP-D Prepared by:REV NO:ECO:- M.Davies 1 Approved by:- UK Head Office: Hi-Force Limited Prospect Way Daventry Northamptonshire NN11 8PL United Kingdom Tel: + 44 1327 301000 Fax: + 44 1327 706555 Email: [email protected] Hi-Force Regional Offices: Hi-Force Australia Pty. Ltd Rockingham Australia Tel: +61 8 9591 1288 Email: [email protected] Hi-Force Caspian Baku Azerbaijan Tel: +994 12 447 4100 Email: [email protected] Hi-Force Hydraulics (Asia) S.B Selangor Malaysia Tel: +603 5569 4209 Email: [email protected] Hi-Force Nederland BV Strijen Netherlands Tel: +31 78 6745488 Email: [email protected] Hi-Force Hydraulics (Pty) Ltd Midrand South Africa Tel: +27 11 314 0555 Email: [email protected] Hi-Force FZCO Dubai United Arab Emirates Tel: +971 4 815 0600 Email: [email protected] Hi-Force Hydraulics Abu Dhabi United Arab Emirates Tel: +971 2 551 3100 Email: [email protected] Hi-Force Hydraulic Equipment (Shanghai) Ltd. Co. Shanghai, China Tel: +86 21 6697 3010 Email: [email protected] GLOBAL BRAND. LOCAL SERVICE. www.hi-force.com Page 16 of 16 1398 Date: 30/03/14