1. MODERN POWERED TORQUING TOOLS
SAFE BOLTING
THE SAFE HANDLING
AND
OPERATION OF
MODERN POWERED TORQUING TOOLS
Welcome to this interactive instruction on safe bolting practices for industry. It’s presented by Hytorc, but it is intended to be general in nature so that the principles discussed can be applied to all brands and models of heavy duty torquing equipment.
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2. ALWAYS FOLLOW CURRENT COMPANY AND LOCAL SAFETY RULES AND PROCEDURES WHEN PERFORMING ANY OF THE WORK DESCRIBED IN THIS PRESENTATION.
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No instruction can cover all possibilities and address all problems. The key is to know what to look for, and where to go to get the answers. Always follow your local safety rules and if you ever have a doubt about the safety of any activity, stop and consult your supervisor.
Remember, nothing is as important as your safety.
The following material is intended to make you aware of the commonly accepted and recognized principles and methods used in assembling bolted joints. However, every possible application of these methods cannot be foreseen and these general guidelines do not supersede any other applicable rules or regulations.

3. World’s Largest Manufacturer of Precision Bolting Tools
10 to 1… HYTORC’s vs any other brand
Hundreds of Industries
Thousands of Applications
You know Hytorc. We’re the world’s oldest and largest manufacturer of precision bolting tools. For every brand-X tool in the marketplace there are 10 Hytorc's in use all over the globe. We’re in hundreds of industries on thousands of applications, from power generation to chemical plants to heavy equipment and oil pipelines. Every time the space shuttle flies, it’s booster rockets were bolted with a Hytorc.

4. SAFETY MISSION STATEMENT
As the world leader in precision industrial bolting technology Hytorc endorses the improvement of bolting safety and commits to:
Lead the industry by example through innovative tool designs and safety-sensitive methods.
Promote safety as the primary justification for customers to invest in its products.
Educate its customers, their employees and contractors, and the general public in why and how to improve safety in their bolting operations regardless of their tooling choices.
Influence business associations, training schools, safety departments, government and industrial standards agencies to adopt and require safer bolting practices for their constituents.
As the world leader in bolting technology, Hytorc is committed to putting safety first in all its products and activities:
To lead by example by designing safer tools
To promote safety in its marketing and sales efforts
To educate everyone who uses its tools in how to improve safety on the job
And to use its influence to get others to adopt and require safer bolting practices

5. LIMITED-CLEARANCE TOOLS
THANK YOU FOR PURCHASING
SAFE BOLTING TABLE OF CONTENTS
SQUARE-DRIVE TOOLS
LIMITED-CLEARANCE TOOLS
HYDRAULIC WRENCHES
HYDRAULIC PUMPS
ELECTRIC PUMPS
SYSTEM OPERATION
SAFELY USING THE TOOLS
AIR PUMPS
TIPS AND TROUBLE-SHOOTING
NEW TOOLS & ACCESSORIES
SOCKET SAFETY
CHARTS
AND HELPS
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6. NOW LET’S REVIEW THE TOOLS

7. Use Personal Protective Equipment
Since we will be dealing with high pressure hydraulics, hard and potentially sharp metal surfaces, and heavy tools and sockets, before we begin we must put on our personal protective equipment.
As a minimum, this should include approved safety glassed with side shields or wrap-around lenses, sturdy gloves and steel-toed shoes. (Depending on the working conditions and local safety rules we may also need a hard hat, other protective footwear, fire or chemical resistant clothing, hearing protection or other specialized gear unique to that job location.)

8. Many Kinds of Bolting Tools
Hydraulic Wrench
impact guns
tensioners
bolt heaters
There are many kinds of bolting tools in use today on heavy industrial joints.
Everything from manual tools, to rattle guns, hydraulic tensioners to bolt heaters.
But the most versatile and widely used heavy bolting tool is the hydraulic wrench, because it delivers tremendous power, with precision in a compact package with interchangeable accessories that fit on hundreds of applications.
cheater bars

9. Modern Hydraulic Wrenches
POWER IN A SMALL SIZE
PRECISE CONTROL AND REPEATABILITY
VERSATILITY
Modern hydraulic wrenches are the most compact, consistent and powerful torquing tools available. The tool contains a hydraulic cylinder which acts like a jack, a drive to engage the nut or bolt, a ratcheting mechanism to allow the drive to reset and a reaction arm to block the tool from turning. They are powered by an external hydraulic pump with variable pressure. Each tool has a known relationship (as shown on a pressure/torque conversion chart) between the desired torque and the required pressure on the pump. Set the pressure and you get the desired torque, no more and no less, subject to the effects of friction and other external factors. Because the oil in the system is not compressible it can be measured very accurately and will give the same results from bolt to bolt.

10. Two Basic Styles
Square Drive Socket Style Wrench with Adjustable Reaction Arm
Hydraulic wrenches come in many variations on two basic styles The most common are those which have a square drive and use standard impact sockets. The advantage of these tools is that it is simple and inexpensive to change to a different size nut by changing the socket.
The second type uses special in-line ratcheting links sockets to fit into tight spaces or to pass over protruding studs to reach a nut.
We’ll take a closer look at these in just a moment.
Narrow Clearance Style with Interchangeable Ratcheting Links

11. Choosing The Right Wrench
DOES IT FIT?
DOES IT HAVE
ENOUGH POWER?
Choosing the right style model of wrench for a specific job is a matter of “fit” and “power”. Will the tool fully engage the nut or bolt and safely react? If it fits, will it have the power to tighten the nut, or what is more difficult, loosen a corroded fastener?
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12. The Square Drive Wrench
(continue with the 3 on the table)
The direction of the wrench, whether to tighten or loosen, is determined by which side of the tool the drive and socket are on. You will note that the drive is offset from the plane of the piston. If we look down on the top of the socket, as the piston travels forward, the drive will be turned in a clockwise direction, tightening the nut.
If we want to loosen a nut, depress the drive retainer button and remove the drive from the wrench. Place it in the opposite side, making sure to align the splines and secure it with the retainer. Readjust the reaction arm, taking care to find a solid surface close to the plane of the nut. Now, when we look down on the socket, as the piston travels forward, the socket will be driven counterclockwise unscrewing the nut.
The direction of the wrench (tighten or loosen) is marked on the side of the tool and is read on the side opposite the socket.
Once the drive is in the correct orientation, reposition the safety handle before proceeding.

13. Torque Ranges by Wrench Size1K 5K
10K
15K
20K
A-20
RECCOMENDED MAX TORQUE
RESERVE
MAX TORQUE
RES.
MAX
A-10
A-5
A-3
As a rule of thumb the maximum torque required for the job should be about 75% of the capacity of the tool. This leaves another 25% reserve power so that the same tool can be used to break loose the bolt after it has been in place for some time. The life of the tool will also be extended if it is not regularly pushed to work at its maximum output.
Since the ranges of the tools overlap, it may be best to choose the next larger tool to ensure enough power, as long as it fits the application.
A-1
Torque in 000’S FT/LBS
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14. Narrow Clearance Wrench

15. RECCOMENDED MAX TORQUE
The same rules apply to the torque ranges of the Narrow Clearance Wrenches
S-22
RECCOMENDED MAX TORQUE
RESERVE
MAX TORQUE
RES.
MAX
S-14
S-8
The same rules apply to the torque ranges of the narrow clearance wrenches in applications where extreme space restrictions or long studs are involved.
S-4
S-2 2K 7K
15K
15K
20K
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Torque in 000’S FT/LBS

16. Questions for Review
The power output of a hydraulic wrench depends on the diameter of its piston and what other factor? How is that power regulated and controlled?
How does one change the direction of a square drive wrench from tighten to loosen?
How does one change the direction of a narrow clearance wrench from tighten to loosen?
Output power is function of the diameter of the piston and the pressure
per square inch of hydraulic fluid. The pressure is controlled by adjusting the pressure regulator on the pump.
Remove the drive and place it in the opposite side of the wrench.
Turn the wrench over.
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17. Questions for Review
True or False
To minimize “side loading” of a stud, the reaction arm of the tool should rest in the same plane as the nut?
Why is it generally a good practice to use only up to about ¾ of the capacity of a wrench to tighten?
True: The reaction arm should abut a solid surface in the same plane as the nut, or as close as possible.
Generally it will take more power to break a nut or bolt loose than
it did to tighten it. In order to use the same wrench for both, it is
usually advisable to not use the entire capacity of the wrench to tighten.
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18. Principles & Types of Hydraulic Pumps
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19. Electric Powered Pumps
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20. Air Powered Pumps Click here to return to Table of Contents,
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21. System Operation Click here to return to Table of Contents,
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22. Questions for Review
True or False:
It would be a good idea to use an electric powered hydraulic pump in an oil refinery because compressed air is not usually available.
Setting an accurate pump pressure is more important for tightening or for loosening?
False. Most refinery vessels contain flammable liquids or gases. Use of electric motors is not a good idea. An air powered pump is preferred.
Tightening. Loosening only requires enough pressure to break the nut
loose but accuracy is not important.

23. Questions for Review
Can I tell by looking, if the hydraulic oil is still serviceable? How?
Which is the appropriate way to set pump pressure?
Lower to higher
Higher to lower
It doesn’t matter
Yes. Generally if the oil is clear and amber colored it is good.
Lower to higher. This has to do with how gauges accurately measure pressure.
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24. SAFELY OPERATING HYDRAULIC TORQUE WRENCHES
(SELECT TYPE OF WRENCH)
AVANTI (SQUARE DRIVE) WRENCHES
STEALTH (NARROW CLEARANCE) WRENCHES
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25. Safely Operating a Hydraulic Wrench

26. How much torque? Bolt Dia. Nut A/F Torque (Ft/Lbs) 1" 1-5/8" 876
TORQUE CHART for B-7 STUDS
Bolt Dia. Nut A/F Torque (Ft/Lbs)
1" 1-5/8"
1-1/4" 2"
1-1/2" 2-3/8“
1-3/4"
2"
/2“
2-1/2" 3-7/8" 26

27. Tightening this nut and bolt
1-1/4” B-7 stud
TORQUE CHART for B-7 STUDS
Bolt Dia. Nut A/F Torque (Ft/Lbs)
1" 1-5/8"
1-1/4" 2" 1165
1-1/2" 2-3/8“
1-3/4" 2-3/4“
2"
2-1/4"
2-1/2" 3-7/8"
2” Nut
1165 lbs.
1 foot

28. Pressure-Torque Chart
SETTING PUMP PRESSURE
Pressure-Torque Chart
USING AVANTI-3 TOOL DESIRED TORQUE = 1165 FT/LBS PRESSURE = 4,000 PSI
4,000 PSI = Ft. Lbs
Outer Scale – PSI
Inner Scale - BAR

29. Safely Operating a Hydraulic Wrench
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30. Safely Operating a Narrow Clearance
Hydraulic Wrench

31. How much torque? Bolt Dia. Nut A/F Torque (Ft/Lbs) 1" 1-5/8" 876
TORQUE CHART for B-7 STUDS
Bolt Dia. Nut A/F Torque (Ft/Lbs)
1" 1-5/8"
1-1/4" 2"
1-1/2" 2-3/8“
1-3/4"
2"
/2“
2-1/2" 3-7/8" 31

32. Tightening this nut and bolt
1-1/4” B-7 stud
TORQUE CHART for B-7 STUDS
Bolt Dia. Nut A/F Torque (Ft/Lbs)
1" 1-5/8"
1-1/4" 2" 1165
1-1/2" 2-3/8“
1-3/4" 2-3/4“
2"
2-1/4"
2-1/2" 3-7/8"
2” Nut
1165 lbs.
1 foot

33. Pressure-Torque Chart
SETTING PUMP PRESSURE
Pressure-Torque Chart
6,200 PSI = Ft. Lbs
Outer Scale – PSI
Inner Scale - BAR
USING STEALTH-2 TOOL DESIRED TORQUE = 1165 FT/LBS PRESSURE = 6,200 PSI

34. Safely Operating a Narrow-Clearance Hydraulic Wrench
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35. Questions for Review
True or False
The wrench will stall when it has reached the target torque corresponding to the preset pressure?
If p.s.i. will produce 300 ft/lbs of torque with a given wrench, how much torque will result at 7500 p.s.i. with that same wrench?
A nut won’t come loose at the same pressure it was tightened with. What should be done? What if it doesn’t move at 10,000 p.s.i.?
True. It is not necessary to watch the gauge or to stop advancing the
pump at a certain pressure.
900 ft/lbs. The relationship between pressure and torque is essentially
linear, allowing you to interpolate values in the pressure/torque table.
Turn up the pressure.
You will need a larger wrench with more power.
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36. THANK YOU ! Click here to return to table of contents
Thank you for your time and attention.
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37. TIPS AND TROUBLESHOOTING
PUMP MOTOR "CLICKS" BUT WON'T START
PUMP MOTOR RUNS BUT WON'T BUILD PRESSURE
PUMP PRESSURIZES BUT TOOL WON'T ADVANCE
AIR MOTOR RUNS SLOWLY OR PUMP WON'T CYCLE
PUMP WON'T BUILD FULL PRESSURE OR NEEDLE BOUNCES
TOOL LOCKED ON
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38. TIPS AND TROUBLESHOOTING (ELECTRIC PUMP MOTOR “CLICKS” BUT WILL NOT START)
PROBLEM:
ELECTRIC PUMP MOTOR WILL NOT START BUT YOU CAN HEAR A “CLICK” WHEN THE REMOTE IS PRESSED
PROBABLE CAUSES/CURES:
INSUFFICIENT VOLTAGE/AMPERAGE DELIVERED
CHECK VOLTAGE AND MAKE SURE ON 20 AMP CIRCUIT
ELIMINATE EXTENSION CORDS OR ENSURE AT LEAST 12 GAUGE CORD IS USED
LOOSE WIRE IN REMOTE CONTROL OR CIRCUIT BOX
CONSULT YOUR ON-SITE ELECTRICIAN
CALL YOUR SALES REP, OR FOR ASSISTANCE OR FURTHER DIAGNOSIS
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39. TIPS AND TROUBLESHOOTING (PUMP WILL NOT BUILD PRESSURE)
PROBLEM:
PUMP MOTOR RUNS BUT WILL NOT BUILD PRESSURE ON THE GAUGE
PROBABLE CAUSES/CURES:
NO OIL IN THE PUMP
CHECK OIL AND REFILL IF NEEDED – DO NOT RUN DRY!
GAUGE CONNECTOR LOOSE
CHECK AND RE-TIGHTEN GAUGE CONNECTOR
DAMAGE TO ELECTRIC SOLENOID OR AIR VALVE
LOOSE WIRE IN REMOTE CONTROL OR DAMAGE TO AIR CAPILLARY TUBES
CALL YOUR SALES REP, OR FOR ASSISTANCE OR FURTHER DIAGNOSIS
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40. TIPS AND TROUBLESHOOTING (PUMP PRESSURIZES BUT TOOL WON’T ADVANCE)
PROBLEM:
PUMP PRESSURIZES, HOSES STIFFEN BUT TOOL WON’T MOVE)
PROBABLE CAUSE:
ONE OR MORE OF THE CHECK-BALL CONNECTORS HAS LOOSENED OR WAS NOT TIGHTENED FULLY
CURE:
RE-CHECK THE TIGHTNESS OF THE CONNECTORS BOTH AT TOOL AND AT THE PUMP
PUSH THE HOSE INTO THE COUPLING AND FINGER-TIGHTEN THE THREADED COLLAR. DO NOT USE TOOLS, AS YOU WILL BEND THE COLLAR AND MAKE FUTURE CONNECTIONS DIFFICULT!
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41. TIPS AND TROUBLESHOOTING (AIR PUMP RUNS SLOWLY OR WILL NOT RELEASE PRESSURE)
PROBLEM:
AIR PUMP BUILDS PRESSURE VERY SLOWLY OR WILL NOT RELEASE PRESSURE WHEN THE BUTTON IS RELEASED
PROBABLE CAUSES/CURES:
LOW AIR PRESSURE OR VOLUME
ENSURE 100 PSI - ¾” MIN. AIR LINE CU.FT./MINUTE FLOW
AIR LEAKS OR RESTRICTIONS
CHECK AIR CONNECTIONS, HOSES AND F.R.L FOR PROBLEMS
MUFFLER CLOGGED
UNSCREW MUFFLER AND CLEAN
CHECK FOR FROZEN WATER VAPOR IN COLD WEATHER, IF SO ENSURE THAT F.R.L IS CLEAR AND OPERATING PROPERLY
EVACUATE AIR SUPPLY HOSE OF AIR OR WATER BUILDUP
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42. TIPS AND TROUBLESHOOTING (PUMP WON’T BUILD FULL PRESSURE OR NEEDLE BOUNCES)
PROBLEM:
PUMP WON’T BUILD FULL 10,000 PSI OR NEEDLE WILL NOT HOLD STEADY AT THE PRE-SET PRESSURE
PROBABLE CAUSES/CURES:
EXTERNAL OIL LEAK
CHECK FOR ANY ESCAPING OIL FROM PUMP, CONNECTORS, HOSES OR
INTERNAL OIL LEAK IN EITHER TOOLS OR PUMP
DISCONNECT THE HOSE FROM THE PUMP. IF PROBLEM GOES AWAY THEN THE LEAK IS IN THE TOOL
IF PROBLEM PERSISTS, INTERNAL PUMP SEALS ARE LEAKING
CALL YOUR SALES REP, OR FOR ASSISTANCE OR FURTHER DIAGNOSIS
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43. TIPS AND TROUBLESHOOTING (TOOL LOCKED ON)
PROBLEM:
AFTER TORQUING, TOOL IS LOCKED ON AND CAN’T BE REMOVED
PROBABLE CAUSE:
TORSION BUILDUP IN THE BOLT IS PUSHING AGAINST THE REACTION PAWL IN THE TOOL (NOTE: THE REACTION PAWL ENABLES THE TOOL TO REACH FULL TORQUE ON THE BOLT IN SPITE OF TORSION OR WIND-UP)
CURE:
WITHOUT CHANGING THE PUMP PRESSURE, START THE PUMP AND HOLD DOWN THE PUMP REMOTE BUTTON DRIVING THE TOOL FORWARD
WHILE HOLDING THE BUTTON DOWN, LIFT AND HOLD THE REACTION PAWL LEVER OR SLIDE
RELEASE THE REMOTE BUTTON, THE TOOL WILL RELAX AND COME OFF WITHOUT A PROBLEM
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44. CHARTS AND RESOURCES TORQUE CHARTS ’PRESSURE-TO-TORQUE’ CHARTS
FLANGE PATTERN CALCULATOR
(Must be connected to
Internet for these links )
ADDITIONAL TRAINING AND ASSISTANCE
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45. PRESSURE-TORQUE CONVERSION CHARTS
AVANTI (SQUARE DRIVE) WRENCHES
STEALTH (NARROW CLEARANCE) WRENCHES
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46. TORQUE CHARTS UN (unified national) “inch” bolts Metric (ISO) bolts
Torque in Foot-Pounds
Metric (ISO) bolts
Torque in Newton-meters
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47. NEW TOOLS & ACCESSORIES
THE LOAD DISC© IN ACTION
THE CLAMP© IN ACTION
THE FLIP-GUN© IN ACTION
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