TX Series

OPERATION AND MAINTENANCE

MANUAL
TX Series
Low Profile Hydraulic Torque Wrenches
MODELS TX-1, TX-2, TX-4, TX-8, TX-16, TX-32, TX-45

Phone: +1 610-250-5800
Fax: +1 610-250-2700
Toll Free: 1-888-TORCUP-1
Email: [email protected]
1025 Conroy Place, Easton PA 18040 U.S.A.
Website: www.torcup.com
1
 Operational and Maintenance Manual for TorcUP
TX-1, TX-2, TX-4, TX-8, TX-16, TX-32 and TX-45
Low Profile Hydraulic Torque Wrenches
Version 2: 2016 September

NOTICE
Series TX-1, TX-2, TX-4, TX-8, TX-16, TX-32 and TX-45 Low Profile 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 modification 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 fittings. 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 For Technical Support & Information Contact:
all warranties. Repairs should be made only by authorized personnel. Consult TorcUP Inc.
your nearest TorcUP Authorized Service Center. 1025 Conroy Place, Easton, PA 18040 USA
Phone: +1 610-250-5800 Fax:+1 610-250-2700
Refer All Communications to the Nearest TorcUP Office or Distributor.
email: [email protected]

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, Always wear eye

frayed or deteriorated protection
hydraulic hoses when operating or
and fittings. performing
maintenance
on this tool.

Always wear ear Do not carry

protection the tool
when operating by the hose.
this tool.

The Torque Reaction Arm must be

Keep body stance
positioned against a positive stop.
balanced and firm.
Do not use the arm as a dead
Do not overreach
handle. Take all precautions to
when operating this
make certain the operator’s hand
tool.
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 fit 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 (TX-16, TX-32, or TX-45) 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 square drive Dwg. 1
torque wrench 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 profile 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.

SETTING THE TORQUE

After determining the desired torque, use the torque conversion charts on pages 7 to 20 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 confirm
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 Wrench Positions Dwg. 2
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, flange 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, swivels, or inlets.

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 first 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. 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 last time to ensure full total 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 outdoors 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 profile 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 on the
piston rod and wipe a film 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 film of Marine Moly Grease onto the wear surface of both side
plate sleeves and the hubs of the ratchet.
5. Spread a light film 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
 TX Series Wrench Technical & Dimensional Data

Model Number TX-1 TX-2 TX-4 TX-8

Min. Torque (ft/lbs) 45 192 395 830
Max. Torque (ft/lbs) 560 1928 3950 8630
Min. Torque (nm) 61 260 535 1125
Max. Torque (nm) 759 2614 5355 11699
Output Accuracy +/-3% +/-3% +/-3% +/-3%
Repeatability 100% 100% 100% 100%
Duty Cycle 100% 100% 100% 100%
Cylinder Weight (lbs/kg) 1.0/0.5 3.5/1.6 6.0/2.7 11.7/5.0
(lbs) 1.0-1.0 2.4-3.5 5.4-7.6 11.9-14.5
Link Weight
(kg) 0.45-0.45 1.0-1.5 2.4-3.4 5.5-6.5
Length (in/mm) 4.37/111.0 6.45/163.8 7.87/199.9 10.18/258.6
Width (in/mm) 0.78/19.8 1.25/31.8 1.63/41.4 2.05/52.1
Radius (in/mm) 0.23/5.8 0.36/9.1 0.46/11.7 0.54/13.7
Height (in/mm) 3.25/82.6 4.00/101.6 5.60/142.2 7.00/177.8
Hex Range From 1/2”/13mm 3/4”/19mm 1”/27mm 1 7/8”/49mm
Hex Range To 2”/50mm 2 9/16”/65mm 3 1/8”/80mm 4 5/8”/120mm

5
TX Series Wrench Technical & Dimensional Data

Model Number TX-16 TX-32 TX-45

Min. Torque (ft/lbs) 1560 3220 4850
Max. Torque (ft/lbs) 16600 35650 47380
Min. Torque (nm) 2115 4365 6575
Max. Torque (nm) 22503 48327 64239
Output Accuracy +/-3% +/-3% +/-3%
Repeatability 100% 100% 100%
Duty Cycle 100% 100% 100%
Cylinder Weight (lbs/kg) 16.0/7.3 26.0/11.5 29.0/13.0
(lbs) 21.0-28.0 29.0-39.5 29.0-39.5
Link Weight
(kg) 9.5-13.0 13.0-17.9 13.0-17.9
Length (in/mm) 12.93/328.4 15.80/401.3 16.75/425.5
Width (in/mm) 2.50/63.5 3.24/82.3 4.88/124.0
Radius (in/mm) 0.65/16.5 0.93/23.6 0.93/23.6
Height (in/mm) 7.58/192.5 9.50/241.3 10.28/261.1
Hex Range From 2 3/16”/55mm 3 1/8”/80mm 3 1/8”/80mm
Hex Range To 5 5/16”/135mm 7 7/8”/200mm 7 7/8”/200mm

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
 TX-1 Series Cylinder

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Housing TX-1-C01 1
2A Piston Rod TX-1-C03-1 1
2B Piston Cap TX-1-C03-2 1
6 Slider TX-1-C09 2
7 End Cap TX-1-C11 1
9 Link Pin TX-1-C15 1
12 Plunger TX-1-C25 1
13 Plunger Spring TX-1-C26 1
14 Slider Pin TX-1-C27 1
15 Plunger Pin TX-1-C28 1
16 End Plug Seal TX-1-C29 1
17 Rod Seal TX-1-C31 1
19 Piston Seal TX-1-C33 1
20 Rod Bushing TX-1-C51 1
26 Whip Hose - 16” HPH-16”-1/8 2
28 Coupler Set HC-S-100 1

Piston Assembly (2A & 2B) TX-1-C03

21
 TX-1 Series Link

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Side Plate - Left TX-1-L01- #* 1
2 Side Plate - Right TX-1-L02- #* 1
3 Drive Plate TX-1-L03- #* 1
4 Drive Pin TX-1-L05 1
5 Drive Pin Spring TX-1-L07 1
6 Ratchet TX-1-L09- #* 1
7 Drive Segment TX-1-L11- #* 1
11 Spacer Pin TX-1-L17 3
12 Sideplate Sleeves TX-1-L19- #* 2
14 Segment Spring TX-1-L25 1
15 Side Plate Screws TX-1-L29 3
16 Dr. Pin Spring Roll Pin TX-1-L33 1

*part number is dependent upon ratchet link size

22
 TX-2 Series Cylinder

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Housing TX-2-C01 1
2 Piston TX-2-C03 1
6 Slider TX-2-C09 2
7 End Cap TX-2-C11 1
8 Retaining Ring TX-2-C13 2
9 Link Pin TX-2-C15 1
10 End Cover TX-2-C17 1
11 End Cover Screw TX-2-C23 1
14 Slider Pin TX-2-C27 1
16 End Plug Seal TX-2-C29 1
17 Rod Seal TX-2-C31 1
19 Piston Seal TX-2-C33 1
21 Link Retaining Spring TX-2-C53 1
27 Swivel Assembly STX-8M-4M 2
28 Coupler Set HC-S-100 1
40 Seal Insertion Tool ATX-2-ST
23
 TX-2 Series Link

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Side Plate - Left TX-2-L01- #* 1
2 Side Plate - Right TX-2-L02- #* 1
3 Drive Plate TX-2-L03- #* 1
4 Drive Pin TX-2-L05 1
5 Drive Pin Spring TX-2-L07 1
6 Ratchet TX-2-L09- #* 1
7 Drive Segment TX-2-L11- #* 1
8 Upper Spacer TX-2-L13- #* 1
10 Lower Spacer TX-2-L15- #* 1
11 Spacer Pin TX-2-L17 2
12 Sideplate Sleeve TX-2-L19- #* 2
13 Shroud TX-2-L21 1
14 Segment Spring TX-2-L25 1
15 Upper Spacer Screw TX-2-L27 4
16 Lower Spacer Screw TX-2-L29 4
17 Shroud Screw TX-2-L31 2
18 Dr. Pin Spring Roll Pin TX-2-L33 1
*part number is dependent upon ratchet link size
24
 TX-4 Series Cylinder

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Housing TX-4-C01 1
2 Piston TX-4-C03 1
6 Slider TX-4-C09 2
7 End Cap TX-4-C11 1
8 Retaining Ring TX-4-C13 2
9 Link Pin TX-4-C15 1
10 End Cover TX-4-C17 1
11 End Cover Screw TX-4-C23 1
14 Slider Pin TX-4-C27 1
16 End Plug Seal TX-4-C29 1
17 Rod Seal TX-4-C31 1
19 Piston Seal TX-4-C33 1
20 Cylinder Gland TX-4-C51 1
21 Link Retaining Spring TX-4-C53 1
27 Swivel Assembly STX-4M-4M 2
28 Coupler Set HC-S-100 1
40 Seal Insertion Tool ATX-4-ST
41 Gland Removal Tool ATX-4-GW
25
 TX-4 Series Link

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Side Plate - Left TX-4-L01- #* 1
2 Side Plate - Right TX-4-L02- #* 1
3 Drive Plate TX-4-L03- #* 1
4 Drive Pin TX-4-L05 1
5 Drive Pin Spring TX-4-L07 1
6 Ratchet TX-4-L09- #* 1
7 Drive Segment TX-4-L11- #* 1
8 Upper Spacer TX-4-L13- #* 1
10 Lower Spacer TX-4-L15- #* 1
11 Spacer Pin TX-4-L17 2
12 Sideplate Sleeve TX-4-L19- #* 2
13 Shroud TX-4-L21 1
14 Segment Spring TX-4-L25 1
15 Upper Spacer Screw TX-4-L27 4
16 Lower Spacer Screw TX-4-L29 4
17 Shroud Screw TX-4-L31 2
18 Dr. Pin Spring Roll Pin TX-4-L33 1

*part number is dependent upon ratchet link size

26
 TX-8 Series Cylinder

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Housing TX-8-C01 1
2 Piston TX-8-C03 1
6 Slider TX-8-C09 2
7 End Cap TX-8-C11 1
8 Retaining Ring TX-8-C13 2
9 Link Pin TX-8-C15 1
10 End Cover TX-8-C17 1
11 End Cover Screw TX-8-C23 1
14 Slider Pin TX-8-C27 1
16 End Plug Seal TX-8-C29 1
17 Rod Seal TX-8-C31 1
19 Piston Seal TX-8-C33 1
20 Cylinder Gland TX-8-C51 1
21 Link Retaining Spring TX-8-C53 1
27 Swivel Assembly STX-4M-4M 2
28 Coupler Set HC-S-100 1
40 Seal Insertion Tool ATX-8-ST
41 Gland Removal Tool ATX-8-GW
27
 TX-8 Series Link

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Side Plate - Left TX-8-L01- #* 1
2 Side Plate - Right TX-8-L02- #* 1
3 Drive Plate TX-8-L03- #* 1
4 Drive Pin TX-8-L05 1
5 Drive Pin Spring TX-8-L07 1
6 Ratchet TX-8-L09- #* 1
7 Drive Segment TX-8-L11- #* 1
8 Upper Spacer TX-8-L13- #* 1
10 Lower Spacer TX-8-L15- #* 1
11 Spacer Pin TX-8-L17 2
12 Sideplate Sleeve TX-8-L19- #* 2
13 Shroud TX-8-L21- #* 1
14 Segment Spring TX-8-L25 1
15 Upper Spacer Screw TX-8-L27 4
16 Lower Spacer Screw TX-8-L29 4
17 Shroud Screw TX-8-L31 2
18 Dr. Pin Spring Roll Pin TX-8-L33 1

*part number is dependent upon ratchet link size

28
 TX-16 Series Cylinder

Part Numbers for Ordering

ITEM NAME PART # QTY. ITEM NAME PART # QTY.
1 Housing TX-16-C01 1 19 Piston Seal TX-16-C33 1
2A Piston Rod TX-16-C03-1 1 20 Cylinder Gland TX-16-C51 1
2B Piston Cap TX-16-C03-2 1 21 Link Retaining Spring TX-16-C53 1
3 Valve Ball TX-16-C03-3 1 22 Seal Plate TXU-16-C54 1
4 Valve Spring TX-16-C03-4 1 23 O-ring (Large) USL-11 1
5 Valve Cup TX-16-C03-5 1 24 O-ring (Small) USL-13 4
6 Slider TX-16-C09 2 25 Seal Plate Screw USL-23 4
7 End Cap TX-16-C11 1 27 Swivel Assembly STX-4M-4M 2
9 Link Pin TX-16-C15 1 28 Coupler Set HC-S-100 1
14 Slider Pin TX-16-C27 1 41 Gland Removal Tool ATX-16-GW
16 End Plug Seal TX-16-C29 1
17 Rod Seal TX-16-C31 1 Piston Assembly
TX-16-C03
(2A, 2B, 3, 4, 5)

29
 TX-16 Series Link

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Side Plate - Left TX-16-L01- #* 1
2 Side Plate - Right TX-16-L02- #* 1
3 Drive Plate TX-16-L03- #* 1
4 Drive Pin TX-16-L05 1
5 Drive Pin Spring TX-16-L07 1
6 Ratchet TX-16-L09- #* 1
7 Drive Segment TX-16-L11- #* 1
8 Upper Spacer TX-16-L13 1
9 Middle Spacer TX-16-L14- #* 1
10 Lower Spacer TX-16-L15- #* 1
11 Spacer Pin TX-16-L17 2
12 Sideplate Sleeve TX-16-L19- #* 2
13 Shroud TX-16-L21 1
14 Segment Spring TX-16-L25 1
15 Upper Spacer Screw TX-16-L27 4
16 Lower Spacer Screw TX-16-L29 4
17 Shroud Screw TX-16-L31 2
18 Dr. Pin Spring Roll Pin TX-16-L33 1
19 Spacer Roll Pin TX-16-L35 1

*part number is dependent upon ratchet link size

30
 TX-32 Series Cylinder

Part Numbers for Ordering

ITEM NAME PART # QTY. ITEM NAME PART # QTY.
1 Housing TX-32-C01 1 19 Piston Seal TX-32-C33 1
2A Piston Rod TX-32-C03-1 1 20 Cylinder Gland TX-32-C51 1
2B Piston Cap TX-32-C03-2 1 21 Link Retaining Spring TX-32-C53 1
3 Valve Ball TX-32-C03-3 1 22 Seal Plate TXU-32-C54 1
4 Valve Spring TX-32-C03-4 1 23 O-ring (Large) USL-11 1
5 Valve Cup TX-32-C03-5 1 24 O-ring (Small) USL-13 4
6 Slider TX-32-C09 2 25 Seal Plate Screw USL-23 4
7 End Cap TX-32-C11 1 27 Swivel Assembly STX-4M-4M 2
9 Link Pin TX-32-C15 1 28 Coupler Set HC-S-100 1
14 Slider Pin TX-32-C27 1 41 Gland Removal Tool ATX-32-GW
16 End Plug Seal TX-32-C29 1
17 Rod Seal TX-32-C31 1 Piston Assembly
TX-32-C03
(2A, 2B, 3, 4, 5)

31
 TX-32/45 Series Link

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Side Plate - Left TX-32-L01- #* 1
2 Side Plate - Right TX-32-L02- #* 1
3 Drive Plate TX-32-L03- #* 1
4 Drive Pin TX-32-L05 1
5 Drive Pin Spring TX-32-L07 1
6 Ratchet TX-32-L09- #* 1
7 Drive Segment TX-32-L11- #* 1
8 Upper Spacer TX-32-L13 1
9 Middle Spacer TX-32-L14- #* 1
10 Lower Spacer TX-32-L15- #* 1
11 Spacer Pin TX-32-L17 2
12 Sideplate Sleeve TX-32-L19- #* 2
13 Shroud TX-32-L21 1
14 Segment Spring TX-32-L25 1
15 Upper Spacer Screw TX-32-L27 4
16 Lower Spacer Screw TX-32-L29 4
17 Shroud Screw TX-32-L31 2
18 Dr. Pin Spring Roll Pin TX-32-L33 1
19 Spacer Roll Pin TX-32-L35 1

*part number is dependent upon ratchet link size

32
 TX-45 Series Cylinder

Part Numbers for Ordering

ITEM NAME PART # QTY.
1 Housing TX-45-C01 1
2A Piston Rod TX-45-C03-1 1
2B Piston Cap TX-45-C03-2 1
3 Valve Ball TX-45-C03-3 1
4 Valve Spring TX-45-C03-4 1
5 Valve Cup TX-45-C03-5 1
6 Slider TX-45-C09 2
7 End Cap TX-45-C11 1
9 Link Pin TX-45-C15 1
14 Slider Pin TX-45-C27 1
16 End Plug Seal TX-45-C29 1
17 Rod Seal TX-45-C31 1
18 Piston Cup Seal TX-45-C32 1
19 Piston Seal TX-45-C33 1
20 Rod Bushing TX-45-C51 1
21 Link Retaining Spring TX-45-C53 1
27 Swivel Assembly STX-4M-4M 2
28 Coupler Set HC-S-100 1
41 Gland Removal Tool ATX-45-GW

Piston Assembly (2A, 2B, 3, 4, 5) TX-45-C03

33
 MAINTENANCE SECTION
Always turn off the power supply. Bleed off hydraulic fluid from the hose
connections on the cylinder assembly and disconnect the hoses before
WARNING attempting to repair or perform maintenance on this tool. Always wear
eye protection when operating or performing maintenance on this tool.

DISASSEMBLY
GENERAL INSTRUCTIONS

1. Do not disassemble the tool any further than necessary to replace or repair damaged parts.
2. Use extra care not to score, nick or damage surfaces that will contain hydraulic oil under pressure.
3. Whenever grasping a tool in a vise, always use leather–covered or copper–covered vise jaws to
protect the surface of the part and help prevent distortion. This is particularly true of threaded
members and housings.
4. Do not remove any part that is press fit in or on an assembly unless the removal of that part is
necessary for repairs or replacement.
5. Do not disassemble the hydraulic cylinder assembly unless you have a complete set of seals and
O–rings for replacement.
6. Use only British Standard fractional size tools when disassembling these tools.

DISASSEMBLY OF THE TOOL

1. Push the link pin (9) out of the housing (1) and side plates (1 & 2).
2. Lift the housing from between the side plates and separate the two units.

DISASSEMBLY OF THE TX-1 CYLINDER ASSEMBLIES

1. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end upward, using
a wrench, unscrew and remove the two whip hoses (26) with their attached couplers (28).
2. Remove the housing assembly from the vise jaws and turn over a container to catch any oil
remaining inside the cylinder.
3. Re-clamp the housing in the vise with the inlet end upward.
4. Using a wrench on the hex of the end plug wrench, unscrew and remove the end cap (7) with the
end plug seal (16).
5. Using a socket on the hex of the piston cap (2B), unscrew and remove the piston cap from the
piston rod (2A).
6. Remove the housing from the vise and turn over a container to empty any remaining oil from the
housing.
7. Re-clamp the housing in the vise and remove the piston rod (2A) from the housing. If necessary,
tap the threaded end of the piston rod with a brass tap being careful not to damage the threads.
8. Press the brass bushing (20), from the piston rod end of the housing, out of the housing.
9. To remove the sliders (6), position the slider pin (14) over a clearance opening in a soft block and
use a small drift to tap the pin out of the sliders and the piston rod.

34
 MAINTENANCE SECTION
DISASSEMBLY OF THE TX-2, TX-4, AND TX-8 CYLINDER ASSEMBLIES

1. Place the tool with the slider pin hole over a clearance opening and use a small drift to tap the slider
pin (14) out of the sliders (6) and piston (2).
2. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end upward, using
a 1/4” hex wrench, unscrew and remove the two swivel assemblies (27) with their attached couplers
(28).
3. Remove the housing assembly from the vise jaws and turn over a container to catch any oil
remaining inside the cylinder.
4. Re-clamp the housing in the vise with the inlet end upward.
5. Use a hex wrench to unscrew and remove the end cover screw (11). Remove the end cover (10).
6. Tap the end cap (7) inward approximately 1/2” and remove the two retaining rings (8) by working
them out of the groove in the cylinder. Note: Covering the oil ports with a cloth will contain any oil
that may expel from the housing.
The purpose of the seal insertion tool in the following step is to prevent
the end plug seal from expanding into the retaining ring groove. If the
CAUTION tool is not used, place two thin pieces of flat stock at the midpoint of the
opening against opposite walls to control the seal expansion.

7. Install the seal insertion tool (40) on the inlet end of the housing. Note: Lubricating the inside of the
insertion tool will ease in the removal of the piston (2) and end cap (7).
8. Invert the tool above the vice. Place a cloth draped between the jaws of the vice to contain the
exiting parts. Spread the vice open enough to catch the end plug and piston.
9. Tap the piston with a brass tap lightly until both the piston and end cap slip through the housing and
into the catch cloth.
10. Use the gland removal tool (41) to unscrew and remove the cylinder gland (20) from the housing.
Note: The TX-2 does not have a cylinder gland.
During removal and after the piston shaft is removed; DO NOT grasp the
round portion of the shaft with any holding device that will damage the
NOTICE surface. Any nicks or scratches to the surface will allow hydraulic oil to
leak from the cylinder when the tool is reassembled.

DISASSEMBLY OF THE TX-16, TX-32 AND TX-45 CYLINDER ASSEMBLIES

1. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end upward, using
a 1/4” hex wrench, unscrew and remove the two swivel assemblies (27) with their attached couplers
(28).
2. Remove the housing assembly from the vise jaws and turn over a container to catch any oil
remaining inside the cylinder.
3. Re-clamp the housing in the vise with the inlet end upward.
4. Using a socket on the hex of the end cap (7), unscrew and remove the end cap with the end plug
seal.
5. Using a socket on the hex of the piston cap (2B), unscrew and remove the piston cap from the
piston rod (2A).
6. Remove the housing from the vise and turn over a container to empty any remaining oil from the
housing.
7. Re-clamp the housing with the end plug end upward in the vise. Place a cloth between the jaws of
the vice to contain the exiting parts. Gently tap the piston rod (2A) with a brass draft to remove it
from the housing, being careful not to damage the threads.

35
 MAINTENANCE SECTION
8. Reclamp the housing in the vice so that the cylinder gland (20) is visible.
9. Use the gland removal tool (41) to unscrew the cylinder gland (20) from the housing.
10. Place the slider pin in the piston rod over a clearance opening in a soft block. Use a small drift to
tap the pin out of the sliders and piston rod.

Under normal circumstances, the seal plate will not need to be

NOTICE removed for maintenance.

TO REMOVE SEAL PLATE ON TX-16 AND TX-32

1. Unscrew seal plate screws. (25)

2. Remove seal plate (22).
3. Inspect o-rings (23 & 24), replace if needed.
4. Insert seal plate into hole in housing.
5. Use a thread locking compound on plate screws before fastening seal plate to housing.

DISASSEMBLY OF THE RATCHET LINK

1. Lay the ratchet link flat on a workbench with the left side plate (1) downward and using a hex
wrench, unscrew and remove the two lower spacer screws (16). Note: TX-1 ratchet links do not
have Upper Spacers or Lower Spacers.
2. Using a hex wrench, unscrew and remove the two upper spacer screws (15). Note: TX-1 ratchet
links do not have Upper Spacers or Lower Spacers.
3. For series TX-16, TX-32, and TX-45 models: Use a roll pin punch to tap the spacer roll pin (19)
out of the right side plate (2).
4. While applying thumb pressure to the edge of the ratchet (6), carefully lift the side plate off the
assembly.
5. Grasp the ratchet and drive plate (3) and, while maintaining their relationship, lift them both off the
left side plate.
6. Push the ratchet out of the drive plate and remove the drive segment (7) and the segment spring
(14) from the drive plate recess.
When the ratchet is removed from the drive plate, the drive segment
and segment spring will be free to fall from the drive plate recess. Do
NOTICE not allow the drive segment to fall on a hard surface that might chip the
teeth.

7. If the drive pin (4) or drive pin spring (5) must be replaced, use a roll pin punch to push the drive pin
spring roll pin (18) out of the drive plate. Once the pin spring is removed, the drive pin (4) will drop
down to the large opening at the bottom of the slot for easy removal.
8. Lift the lower spacer (10) off the lower spacer pins (11). If the pins must be replaced, use a hex
wrench to remove the two lower spacer screws from the right side plate. Pull the pins out of the
holes on the inner face of the right side plate.
9. For Series TX-2, TX-4, and TX-8 models: Unscrew the two spacer screws and remove the upper
spacer (8) from the right side plate. For Series TX-16, TX-32, TX-45 models: Use a roll pin punch
to remove the spacer roll pin (19) from the right side plate. Unscrew the two spacer screws and
remove the middle spacer (9) and upper spacer (8) from the right side plate.
10. If the side plate sleeves (12) must be replaced, press the sleeves out toward the inner face of the
side plate. Note: TX-1 ratchet links do not have Upper Spacers or Lower Spacers.

36
 MAINTENANCE SECTION

NOTICE Inspect all parts prior to assembly. Replace any worn or damaged parts.

ASSEMBLY

ASSEMBLY OF TX-1 CYLINDER ASSEMBLIES

1. Press the slider pin (14) into one of the sliders (6) until flush with one side. Install the pin through
the hole in the piston rod (2A) and press the remaining slider into the pin.
2. With the inlet end of the housing upward, press the brass bushing (20), with the shoulder trailing,
into the housing.
3. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end downward.
4. Insert the piston rod (2A), threaded end leading, into the small central opening in the housing. The
notch in the trailing end of the rod should be towards the retaining pin hub.
5. Reclamp the housing in the vise with the inlet end upwards.
6. Insert the piston cap (2B), hex end trailing, into the bore of the housing and use a socket to thread
and tighten the piston cap onto the piston rod.
7. Thread the end cap (7), O-ring leading, into the bore of the housing and tighten.
8. Wrap the threads of the whip hoses (26) with Teflon tape.
9. Install the male coupler hose into the end cap port and the female coupler hose into the housing
port

ASSEMBLY OF TX-2, TX-4, AND TX-8 CYLINDER ASSEMBLIES

1. Clamp the housing (1) in copper-covered or leather-covered vise jaws with the inlet end downward.
2. Apply a non-permanent thread-locking compound to the threads of the cylinder gland (20). Use
the gland removal tool (41) to thread the bushing into the small central opening in the housing and
tighten until flush with the housing (1). Note: TX-2 does not have a cylinder gland.
3. Flip the housing (1) in the vise and install the seal insertion tool (40). Note: Lubricating the inside of
the insertion tool and the sides of the piston rod assembly and end cap will ease installation.
4. Insert the piston (2) into the seal insertion tool (41), notched end leading and toward the link pin
hub, and tap into housing approximately 1”.
5. Insert the end cap (7), swivel inlet toward the link pin hub, into the seal insertion tool (40), and tap in
until the piston (2) bottoms out against the housing (1).
6. Install retaining rings (8), tapered edge leading into the grooves in the housing.
7. Flip the housing in the vise and drive the piston (2) into the housing with a brass tap until the end
cap (7) seats in the retaining rings (8).
8. Install the end cover (10), applying a non-permanent thread-locking compound to the end cover
screw (11) threads.
9. Remove the housing from the vice and place on a soft block with the engraved side up.
10. Install sliders (6), one on each side of piston (2). For TX-8 models: Install sliders with the cutout
towards the piston. Align the holes in the sliders with the holes in the piston and the housing.
11. Install slider pin (14) until flush with top slider.
12. Apply moly grease to the face of the sliders and the notch in the piston.
13. Wrap the threads of the swivel assemblies (27) with Teflon tape.
14. Install the male coupler swivel into the end cap port and the female coupler swivel into the housing.

37
 MAINTENANCE SECTION

NOTICE Inspect all parts prior to assembly. Replace any worn or damaged parts.

ASSEMBLY OF TX-16, TX-32 AND TX-45 CYLINDER ASSEMBLIES

1. Press the slider pin (14) into one of the sliders (6) until flush with one side. Install the pin through
the hole in the piston rod (2A) and press the remaining slider into the pin.
2. Clamp the housing in copper-covered or leather-covered vise jaws with the inlet end downward.
3. Apply a non-permanent thread-locking compound to the threads of the cylinder gland (20). Use the
gland removal tool (41) to thread the gland into the small central opening in the housing and tighten
until flush with the housing (1).
4. Insert the piston rod (2A), threaded end leading, into the small cylinder gland in the housing. The
notch in the trailing end of the rod should be towards the retaining pin lug.
5. Reclamp the housing so that the inlet end is upwards.
6. Insert the piston cap (2B), hex end trailing, into the bore of the housing and use a socket to thread
and tighten the piston cap onto the piston rod.
7. Thread the end cap (7), O-ring leading, into the bore of the housing and tighten with a socket.
8. Wrap the threads of the swivel assemblies (27) with Teflon tape.
9. Install the male coupler swivel into the end cap port and the female coupler into the housing port.

ASSEMBLY OF THE RATCHET LINK

1. If the side plate sleeves (12) were removed, press new sleeves, shoulder end trailing, into the right
and left side plates (1 & 2) from the inner face of the side plates. Make certain the sleeves are
square with the side plate faces and that the shoulder of the sleeves enters the recesses in the side
plates and are pressed flush with the faces.
2. For Series TX-2, TX-4, and TX-8 models: Position the upper spacer (8) against the inside face
of the right side plate. Apply a non-permanent thread-locking compound to the threads of the two
upper spacer screws (15) and secure the spacer with the screws through the side plate. For Series
TX-16, TX-32, TX-45 models: Press the spacer roll pin (19) into the right side plate with one end of
the pin flush with the external face of the side plate. Insert the tab of the upper spacer (8) into the
slot in the middle spacer (9). After aligning the holes in both pieces, install them on the spacer roll
pin (19). When they are correctly positioned, apply a non-permanent thread-locking compound to
the threads of the two upper spacer screws (15) and secure the spacers with the screws through
the side plate.
3. Insert the two lower spacer pins (11) into the holes in the lower edge of the right side plate. Apply a
non-permanent thread-locking compound to the threads of the lower spacer screws (16) and secure
the pins with the screws through the side plate. Note: The TX-1 ratchet links do not have Upper
Spacers and Lower Spacers.
4. Place the lower spacer (10) over the pins against the side plate. Make certain it is correctly oriented
so that no part of the spacer extends beyond the edge of the side plate. Note: The TX-1 ratchet
links do not have Upper Spacers and Lower Spacers.
5. Insert the drive pin (4) into the small cross-hole and slot in the drive plate (3). Invert the plate
causing the ends of the pin to enter the slot and move the pin to the narrow end.
6. Position the drive pin spring (5) in the drive plate slot with the two non-connected ends between the
drive pin and the large hole in the slot. Position the closed end of the spring on the opposite side of
the pin and then apply pressure on the spring to align the hole through it with the hole in the drive
plate for the drive pin spring roll pin (18). Insert the spring roll pin into the drive plate, through the
spring and into the far wall of the drive plate.
38
 MAINTENANCE SECTION
In the following step, an excessive amount of grease will prevent
NOTICE proper tooth engagement between the ratchet and the drive
segment, causing the tool to malfunction.

7. Wipe a thin film of Marine Moly Grease onto the inner face of the large opening in the drive plate.
8. Position the ratchet (6) in the central opening of the drive plate.
9. Insert the drive segment (7) into the opening adjacent to the ratchet. Make certain the teeth of
the ratchet correctly engage the teeth of the drive segment. Reverse the ratchet if they do not
properly engage.
10. Slide the drive segment sideways to expose the spring hole. Install the segment spring (14) into the
hole. While compressing the spring, slide the drive segment inward until the drive plate captures
the segment spring.
11. Apply a light coat of Marine Moly Grease to both sides of the drive plate and drive segment as well
as the inner races of both side plate sleeves (12).
12. While keeping the assembly together, insert the hub of the ratchet into the side plate sleeve of the
assembled side plate.
13. Place the left side plate sleeve on the hub of the ratchet and align the screw holes for the spacers.
14. After applying a non-permanent thread-locking compound to the threads and using hex wrenches,
install the two remaining lower spacer screws.
ASSEMBLY OF THE TOOL
1. With the cylinder assembly in one hand and the ratchet link in the other, hook the notch on the
shaft of the piston rod (2A) onto the drive pin (4) and bring the two assemblies together.
2. Insert the link pin (9) into the hole in the side plate (1 or 2) until the link pin snaps into the link
retaining spring (21).

39
 TROUBLESHOOTING GUIDE
Trouble Probable Cause Solution
Couplers are not securely attached Check the coupler connections and
to the tool or pump make certain that they are connected.
Coupler is defective Replace any defective coupler.
Piston will not advance
or retract Replace the switch and/or control
Defective remote control switch
pendent.
Dirt in the direction-control valve of Disassemble the pump and clean the
the pump unit direction-control valve.
Make certain the advance on the pump
is connected to the advance on the tool
Hose connections reversed
and retract on the pump is connected to
Piston will not retract the retract on the tool.
Retract hose not connected Connect the retract hose securely.
Retract pin and/or spring broken Replace the broken pin and/or spring.

Piston seal and/or end plug seal

Replace any defective o-rings.
Cylinder will not build leaking
up pressure Retaining screws sheared Replace any broken screws.
Coupler is defective Replace any defective coupler.
Grease or dirt build up in the teeth
Disassemble the ratchet and clean the
of the ratchet link
grease or dirt out of the teeth.
Ratchet will not turn and drive segment
Worn or broken teeth on ratchet
Replace any worn or damaged parts.
and/or drive segment

Depress the advance button to release

Tool tightens immedi- the tool; shut the pump off in the
Hose connections are reversed
ately when turned on advance position and reverse
the hose connection.
Inspect, adjust or replace
Defective relief valve
the relief valve.
Make certain the air supply and hose
Air supply too low or air hose too
size comply with the pump manual
small
recommendations.
Pump will not build up Make certain the amperage, voltage
pressure Electric power source is too low and any extension cord size comply
with the pump manual requirements.
Defective gauge Replace the gauge.
Low oil level Check and fill the pump reservoir.
Inspect, clean and/or replace
Clogged filter
the pump filter.
Pressure reading
Defective gauge Replace the gauge.
erratic

40
 SAVE THESE INSTRUCTIONS DO NOT DESTROY

NOTES:

Phone: +1 610-250-5800
Fax:+1 610-250-2700
Toll Free: 1-888-TORCUP-1
1025 Conroy Place, Easton, PA. 18040 U.S.A. Email: [email protected]
Website: www.torcup.com