HYTORC Stealth Technical Manual en
HYTORC Stealth Technical Manual en
HYTORC Stealth Technical Manual en
Technical manual
Introduction
Copyright
2
Contents
Contents
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 Electric and pneumatic pump units................................................................................... 9
2.2.2 Electric pump units............................................................................................................9
2.2.3 Hydraulic hoses.................................................................................................................9
2.2.4 Reaction arms................................................................................................................. 10
2.2.5 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 Electric pump unit...................................................................................................................... 13
3.3.1 LED indicators (electric pump unit)................................................................................. 13
3.4 Pneumatic pump unit................................................................................................................. 14
3.5 Hydraulic limited-clearance wrench........................................................................................... 15
3.6 Accessories................................................................................................................................16
3.6.1 Safety handle.................................................................................................................. 16
3.6.2 BoltSafe load tester.........................................................................................................16
3.6.3 Torque and angle sensor................................................................................................ 16
3.6.4 Insert............................................................................................................................... 17
3.6.5 Stacking nuthead............................................................................................................ 18
3.6.6 Male hex drive.................................................................................................................18
4 Installation..............................................................................................19
4.1 Hydraulic hoses......................................................................................................................... 19
4.1.1 Hydraulic hose connections............................................................................................ 19
4.1.2 Connecting the hydraulic hoses...................................................................................... 20
4.1.3 Disconnecting the hydraulic hoses..................................................................................21
4.2 Power supply (electric pump units)............................................................................................ 22
4.2.1 Connecting the power supply (230V).............................................................................. 22
4.2.2 Connecting the power supply (400V).............................................................................. 22
-- 3
Contents
5 Reaction arms........................................................................................24
5.1 Reaction pad..............................................................................................................................24
5.2 Alco reaction arm....................................................................................................................... 24
5.3 Interconnect reaction arm.......................................................................................................... 25
5.4 Holding plate..............................................................................................................................25
6 Operation............................................................................................... 26
6.1 Inspections before use...............................................................................................................26
6.2 Remote control...........................................................................................................................26
6.2.1 Electric pump unit............................................................................................................26
6.2.2 Pneumatic pump unit...................................................................................................... 27
6.3 Disengagement button for reaction pawl................................................................................... 27
6.4 Torque........................................................................................................................................28
6.4.1 Pressure/torque chart......................................................................................................28
6.4.2 Setting the torque............................................................................................................28
6.5 Replacing the ratchet link...........................................................................................................29
6.6 Determining the direction of rotation.......................................................................................... 30
6.7 Tightening and loosening a bolted flange connection................................................................30
6.7.1 Tightening a bolted flange connection............................................................................ 31
6.7.2 Loosening a bolted flange connection.............................................................................31
6.8 Automatic shut-off system..........................................................................................................32
6.9 Thermal protection..................................................................................................................... 32
7 Maintenance.......................................................................................... 33
7.1 Preventive maintenance............................................................................................................ 33
7.2 Maintenance by HYTORC......................................................................................................... 33
8 Storage.................................................................................................. 34
8.1 Storing the cables...................................................................................................................... 34
9 Troubleshooting..................................................................................... 35
9.1 Tools.......................................................................................................................................... 35
9.2 Pump units.................................................................................................................................36
9.2.1 General........................................................................................................................... 36
9.2.2 Electric pump units..........................................................................................................36
9.2.3 Pneumatic pump units.....................................................................................................37
10 Technical data........................................................................................38
10.1 Stealth 2.....................................................................................................................................38
10.2 Stealth 4.....................................................................................................................................38
10.3 Stealth 8.....................................................................................................................................39
10.4 Stealth 14...................................................................................................................................39
10.5 Stealth 22...................................................................................................................................39
10.6 Stealth 36...................................................................................................................................39
10.7 Swivel rotation............................................................................................................................40
10.8 Physical conditions.................................................................................................................... 40
10.9 Maximum torque values (stacking nutheads and male hex drives)........................................... 40
4 --
Contents
11 Declaration of Conformity...................................................................... 43
12 Parts list................................................................................................. 44
-- 5
About the document
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.
6 37 - 001 -
About the document
User manual
37 - 001 - 7
Safety
2 Safety
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.
• In most cases, the tool will allow hands-free operation. If the tool must be held or
steadied during operation, use alternative means of securing the tool to the
application.
• 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.
8 37 - 001 -
Safety
37 - 001 - 9
Safety
ุPP
• Make sure that the reaction arm is locked onto 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.
2.2.5 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.
10 37 - 001 -
Safety
• 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.
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.
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
37 - 001 - 11
Description
3 Description
3.2 Overview
12 37 - 001 -
Description
4
37 - 001 - 13
Description
Indication Description
Green, continuous The pump unit is ready for use.
Indication Description
Green, continuous The pump unit is ready for use.
Red, flashing (2x) The direction of rotation is incorrect. Reverse
the polarity of the phase inverter plug.
Red, continuous Error.
14 37 - 001 -
Description
5
$
1 Hose connection (male coupling) (supply 6 Disengagement button for reaction pawl
hose) (A)
2 Hose connection (female coupling) (re- 7 Mounting point for safety handle
turn hose) (R)
3 Ratchet link (interchangeable) 8 Mounting holes for holding plate
4 Link release button 9 Hex drive or Hytorc nut drive
5 Link pin
37 - 001 - 15
Description
3.6 Accessories
3.6.1 Safety handle
Procedure
16 37 - 001 -
Description
Procedure
3.6.4 Insert
Procedure
37 - 001 - 17
Description
18 37 - 001 -
Installation
4 Installation
3803 722/
3803 722/
3803 722/
Note: An odd number of hoses is required to extend the hydraulic hose. You
cannot use an even number of hoses. "PUMP" refers to the electric pump
unit. "TOOL" refers to the tool.
37 - 001 - 19
Installation
20 37 - 001 -
Installation
• Make sure that the hydraulic hoses are securely connected to both the
pump unit and the tool. Make sure that there is no clearance between the
male couplings and the female couplings. If the hydraulic hoses become
loose, no hydraulic oil will flow through the hoses and the tool will not
operate.
Procedure
Procedure
37 - 001 - 21
Installation
22 37 - 001 -
Installation
37 - 001 - 23
Reaction arms
5 Reaction arms
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.
24 37 - 001 -
Reaction arms
37 - 001 - 25
Operation
6 Operation
26 37 - 001 -
Operation
37 - 001 - 27
Operation
6.4 Torque
6.4.1 Pressure/torque chart
The maximum operating pressure for all HYTORC pump units is 690 bar (10,000 psi).
Warning:
• Make sure that the maximum operating pressure of the pump unit is not
higher than the maximum permitted pressure of 690 bar (10,000 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 (Stealth 2)
Pressure Torque
bar psi Nm ft.lb.
104 1,500 377 278
110 1,600 403 297
124 1,800 456 336
138 2,000 508 375
152 2,200 559 413
165 2,400 610 450
179 2,600 661 488
Procedure
28 37 - 001 -
Operation
5. Press and hold the start button (C) on the remote control until the square drive no
longer turns.
The piston in the tool is in the fully extended position.
Note: If the piston does not move, turn the pressure control valve (B)
360° clockwise.
37 - 001 - 29
Operation
30 37 - 001 -
Operation
Note: If the pressure gauge increases to the set value, this does not
indicate that the required torque is applied to the nut or the bolt. It only
indicates that the piston in the tool cannot turn the socket further until the
tool automatically resets itself.
4. Release the start button (B) on the remote control.
The piston in the tool moves to the fully retracted position. An audible click will
sound.
5. Repeat steps 3 and 4 until the nut or the bolt no longer turns.
The nut or the bolt has been tightened with a torque accuracy of ±3%.
37 - 001 - 31
Operation
Procedure
32 37 - 001 -
Maintenance
7 Maintenance
37 - 001 - 33
Storage
8 Storage
34 37 - 001 -
Troubleshooting
9 Troubleshooting
Try to find a solution for the problem using the tables. If you cannot find a solution for the
problem, contact your local HYTORC representative.
9.1 Tools
Problem Possible cause Solution
The tool does not move. The hose couplings on the tool Securely tighten the female
and the pump unit are not se- coupling to the male coupling.
cured properly.
The tool stalls. The reaction pawl was not acti- See Disengagement button for
vated. reaction pawl on page 27.
The piston in the tool does not The hose couplings on the tool Securely tighten the female
retract. and the pump unit are not se- coupling to the male coupling.
cured properly.
The linkage between the piston Replace the defective part.
and the drive arms is damaged.
The pressure in the system There is oil leakage due to a Replace the defective part.
does not increase. defective piston, piston seal or
O-ring.
There is leakage in the pres- Tighten the leaking connection.
sure relief valve and/or the two Use a 9/16” open-end wrench.
oil line connections.
A motor coupling is worn. The Replace the motor coupling.
pump makes sounds like peb-
bles in a tin can.
The air shut-off valve fails due Clean the air shut-off valve and
to excessive moisture and/or the air lines.
dirt in the air supply.
The valve in the remote control Replace the valve in the remote
fails. control.
The tool leaks externally. Blind plugs or end caps are Replace the blind plugs and/or
worn/damaged or not secured. the end caps.
The O-ring or the gland seal in Replace the defective part.
the piston is defective.
The tool operates backwards. An even number of hoses has Connect an odd number of ho-
been connected. ses. See Hydraulic hose con-
nections on page 19.
The male coupling and the fe- Use a HYTORC twin hose.
male coupling have been inter-
changed.
The tool moves slower than There is a leakage in the sys- Adjust the pump pressure to
usual. tem. 700 bar (10,000 psi) and switch
off the pump unit while holding
the start button. The pump
pressure must decrease to 100
bar (1,450 psi). If the pump
pressure decreases to 0 bar (0
psi), contact your local HY-
TORC representative.
The ratchet returns with a The square drive is defective. Replace the defective part.
stroke.
37 - 001 - 35
Troubleshooting
36 37 - 001 -
Troubleshooting
37 - 001 - 37
Technical data
10 Technical data
5
+(;
: /
10.1 Stealth 2
Length (L) 140.5 mm 5.53"
Height (H) 106.9 mm 4.21"
Width (W) 31.8 mm 1.25"
Hex link, min 19 mm 3/4"
Hex link, max 35 mm 1 3/8"
Radius (R), min 26.1 mm 1.03"
Radius (R), max 44.6 mm 1.76"
Minimum torque 377 Nm 278 ft.lbs.
Maximum torque 2,534 Nm 1,869 ft.lbs.
Weight 2.3 kg 5.1 lbs.
10.2 Stealth 4
Length (L) 167.1 mm 6.56"
Height (H) 138.0 mm 5.43"
Width (W) 42.2 mm 1.66"
Hex link, min 35 mm 1-3/8"
Hex link, max 44 mm 1-3/4"
Radius (R), min 33.6 mm 1.32"
Radius (R), max 58.9 mm 2.32"
Minimum torque 819 Nm 604 ft.lbs.
Maximum torque 5,450 Nm 4,020 ft.lbs.
Weight 4.9 kg 10.8 lbs.
38 37 - 001 -
Technical data
10.3 Stealth 8
Length (L) 203.2 mm 8.00"
Height (H) 162.6 mm 6.40 "
Width (W) 53.3 mm 2.10 "
Hex link, min 44 mm 1-3/4"
Hex link, max 64 mm 2-1/2"
Radius (R), min 44.88 mm 1.77"
Radius (R), max 73.4 mm 2.89"
Minimum torque 1,625 Nm 1,199 ft.lbs.
Maximum torque 10823 Nm 7,984 ft.lbs.
Weight 9.2 kg 20.3 lbs.
10.4 Stealth 14
Length (L) 237.4 mm 9.35 "
Height (H) 201.7 mm 7.94 "
Width (W) 63.5 mm 2.50 "
Hex link, min 50 mm 2"
Hex link, max 70 mm 2-3/4"
Radius (R), min 59.2 mm 2.33"
Radius (R), max 88.2 mm 3.47"
Minimum torque 2,854 Nm 2,105 ft.lbs.
Maximum torque 19,324 Nm 14,255 ft.lbs.
Weight 15.4 kg 34.0 lbs.
10.5 Stealth 22
Length (L) 274.3 mm 10.80"
Height (H) 233.2 mm 9.18"
Width (W) 73.9 mm 2.91"
Hex link, min 70 mm 2-3/4"
Hex link, max 95 mm 3-3/4"
Radius (R), min 66.6 mm 2.62"
Radius (R), max 98.4 mm 3.87"
Minimum torque 4,406 Nm 3,250 ft.lbs.
Maximum torque 29,654 Nm 21,875 ft.lbs.
Weight 28.5 kg 62.8 lbs.
10.6 Stealth 36
Length (L) 322.8 mm 12.71"
Height (H) 274.6 mm 10.78"
Width (W) 86.6 mm 3.41"
37 - 001 - 39
Technical data
6
6
Note: The tool is not suitable for use in explosive environments. Your HYTORC deal-
er is able to modify your HYTORC equipment (except for electric tools) to comply
with the directives EPS 13 ATEX 2 561 X and EX II 2 G EX c IIB T4.
40 37 - 001 -
Technical data
37 - 001 - 41
Technical data
42 37 - 001 -
Declaration of Conformity
11 Declaration of Conformity
Declaration of Conformity
We,
HYTORC BV
Platinawerf 8, 6641 TL Beuningen
The Netherlands
Name: HYTORC
37 - 001 - 43
Parts list
12 Parts list
Cylinder parts list
44 37 - 001 -
Parts list
37 - 001 - 45
Parts list
Note: Replace the # in the part numbers with the link blank size.
46 37 - 001 -
Parts list
37 - 001 - 47