Version 1-2000
November 2000
OPERATION AND MAINTENANCE MANUAL
FOR TX 2, 4, 8, 16, 32
LOW PROFILE HYDRAULIC TORQUE WRENCHES
Series TX-2, TX-4, TX-8, TX-16 and TX-32 Low Profile Hydraulic Torque Wrenches are designed for
installing and removing large bolts having minimal wrench clearance at offshore platforms, power
plants, steel erection sites and other locations requiring precise high torque during bolt makeup and
maximum torque for bolt breakdown.
Aztec Bolting Services is not responsible for customer modification of tools for applications on which
Aztec Bolting Services was not consulted.
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
.
PLACING TOOL IN SERVICE
•
Use the quick connect system to attach the hoses to the
tool and pump. Make certain the spring-loaded retaining
rings are fully engaged and the safety rings are tightly
threaded against the spring-loaded retaining rings to
prevent the connectors from disengaging under pressure.
When connecting hoses that have not been preloaded
with hydraulic oil, make certain the pump reservoir is
not drained of oil during start-up.
• 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.
Do not remove any labels. Replace any damaged labels.
USING THE TOOL
• Use only a hydraulic pump capable of generating
10,000 psig (681 bar) maximum pressure with this tool.
• Use only twin line hydraulic hose rated for 10,000 psig
(681 bar) pressure with this tool.
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..
•
•
•
• 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.
Always wear head and hand protection and protective
clothing when operating this tool.
The use of other than genuine replacement parts may result in safety hazards, decreased tool performance, and
increased maintenance, and may invalidate all warranties.
Repairs should be made only by authorized personnel. Refer all communications to Aztec Bolting Services
For Technical Support and Information Contact:
Printed in U.S.A.
Aztec Bolting Services, Inc.
520 Dallas Street
League City, TX 77573
Toll Free: (800) 233-TORK
Fax: (281) 332-1780
E-mail: [email protected]
- 1 -
PLACING THE TOOL IN SERVICE
NOT allow the tool to react against the hoses, swivels,
or inlets.
ADJUSTMENTS
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.
SETTING THE TORQUE
After determining the desired torque, use the torque con-
version chart on the Shroud or the torque conversion
charts on pages 5 and 6 to determine the pressure that is
necessary to achieve that torque.
1. Connect the tool to the power supply and turn the
pump on.
4. When the Link is connected to the Housing and the
wrench is started, the reaction surface of the wrench will
move against the contact point and the nut will begin to
turn.
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.
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 and 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. Once the nut stops rotating, cycle the tool one last
time to achieve total torque.
OPERATING THE WRENCH
LUBRICATION
Wrench Positions
Dwg. 2
Marine Grade Moly Lube
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 out-doors and dropped in loose dirt or sand.
Marine Grade Moly Lube 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 Driver Assembly from the
Ratchet Link if they are joined.
SHROUD
TIGHTEN
LOOSEN
2. After wiping of the old grease, apply a daub of Marine
Grade Moly Lube to the hooking notch in the Piston
rod and wipe a film of Moly Lube onto the sides and
faces of the two Sliders.
REACT BETWEEN THESE POINTS
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
Grade Moly Lube onto the wear surface of both Side
Plate Sleeves and the hubs of the Ratchet.
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 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.
5. Spread a light film of Marine Grade Moly Lube onto
the inner faces of both Side Plates covering the area
where the Drive and Segment Pawl travel. DO NOT
pack the teeth of the Segment Pawl or Ratchet with
lube. It can prevent the teeth from engaging properly.
6. Reassemble the Ratchet Link as instructed in the
Maintenance Section.
2. Position the reaction surface against an adjacent nut,
flange or solid system component. Make certain that
there is clearance for the hoses, swivels, or inlets. DO
- 3 -
TX Series Torque Conversion Chart
Bar/N.M.
TX-2
TX-4
TX-8
TX-16
TX-32
Hex
Sizes
Bar
3/4" to 1-13/16" 1-7/8" to 2-3/8" All Hex Sizes All Hex Sizes 2-5/8" to 3-15/16" 4" to 4-5/8" 2-7/16" to 4-5/8"4-11/16" to 6-1/2"
19 to 46MM
N.m.
47 to 60MM All Hex Sizes All Hex Sizes 65 to 100MM 105 to 115MM 80 to 115MM
115 to 155MM
N.m.
N.m.
285
N.m.
N.m.
1,125
1,357
1,590
1,822
2,055
2,288
2,528
2,768
3,008
3,248
3,489
3,762
4,034
4,307
4,579
4,853
5,063
5,275
5,485
5,696
5,908
6,152
6,396
6,640
6,884
7,128
7,334
7,540
7,747
7,953
8,161
8,386
8,611
8,837
9,062
9,289
9,520
9,754
9,985
10,219
10,452
10,701
10,951
11,200
11,449
11,699
N.m.
N.m.
N.m.
68
260
312
535
2,115
2,250
#VALUE!
#VALUE!
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#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
5,016
6,019
82
342
644
2,535
2,700
95
365
399
752
2,955
3,150
7,022
109
122
136
150
163
177
190
204
218
231
245
258
272
286
299
313
326
340
354
367
381
394
408
422
435
449
462
476
490
503
517
530
544
558
571
585
598
612
626
639
653
666
680
416
455
854
3,382
3,600
8,025
469
512
962
3,802
4,051
9,028
522
569
1,071
1,179
1,288
1,389
1,498
1,606
1,715
1,823
1,925
2,033
2,142
2,250
2,359
2,460
2,569
2,677
2,786
2,894
2,996
3,104
3,213
3,321
3,430
3,531
3,640
3,748
3,857
3,965
4,067
4,175
4,284
4,392
4,501
4,602
4,711
4,819
4,928
5,029
5,138
5,246
5,355
4,229
4,501
10,031
11,035
12,038
13,041
14,044
15,047
16,050
17,053
18,057
19,060
20,063
21,066
22,069
23,072
24,075
25,079
26,082
27,085
28,088
29,091
30,094
31,097
32,101
33,104
34,107
35,110
36,113
37,116
38,119
39,123
40,126
41,129
42,132
43,135
44,138
45,141
46,145
47,148
48,151
49,154
50,157
572
626
4,650
4,951
625
683
5,070
5,401
678
740
5,490
5,851
728
797
5,917
6,301
784
868
6,337
6,751
832
923
6,764
4,826
885
981
7,185
7,651
937
1,038
1,097
1,159
1,212
1,270
1,328
1,385
1,450
1,507
1,566
1,624
1,682
1,742
1,799
1,857
1,914
1,972
2,033
2,089
2,146
2,204
2,262
2,325
2,379
2,437
2,494
2,553
2,615
2,669
2,726
2,784
2,843
2,908
7,605
8,101
990
8,032
8,551
1,045
1,093
1,145
1,197
1,250
1,307
1,353
1,406
1,457
1,510
1,567
1,613
1,666
1,718
1,769
1,829
1,873
1,926
1,979
2,029
2,090
2,134
2,187
2,238
2,291
2,352
2,394
2,447
2,498
2,551
2,614
8,452
9,015
8,879
9,466
9,299
9,916
9,720
10,368
10,818
11,333
11,786
12,240
12,692
13,147
13,692
14,148
14,604
15,061
15,518
15,888
16,342
16,796
17,250
17,630
18,314
18,772
19,231
19,687
20,146
20,361
20,814
21,267
21,718
22,171
22,503
10,147
10,567
10,987
11,414
11,834
12,261
12,682
13,102
13,522
13,949
14,369
14,796
15,217
15,637
16,064
16,484
16,911
17,331
17,752
18,172
18,599
19,019
19,446
19,866
20,287
20,714
21,141
- 4 -
TX Series Torque Conversion Chart
P.S.I./FT./lbs
TX-2
3/4" to 1-13/16" 1-7/8" to 2-3/8" All Hex Sizes All Hex Sizes 2-5/8" to 3-15/16" 4" to 4-5/8" 2-7/16" to 4-5/8" 4-11/16" to 6-1/2"
TX-4
TX-8
TX-16
TX-32
Hex
Sizes
19 to 46MM
ft./lbs.
192
47 to 60MM All Hex Sizes All Hex Sizes 65 to 100MM 105 to 115MM 80 to 115MM
115 to 155MM
ft./lbs.
P.S.I.
ft./lbs.
210
ft./lbs.
395
ft./lbs.
830
ft./lbs.
1,560
1,870
2,180
2,495
2,805
3,120
3,430
3,740
4,050
4,365
4,675
4,990
5,300
5,610
5,925
6,235
6,550
6,860
7,170
7,485
7,795
8,105
8,420
8,730
9,045
9,355
9,665
9,975
10,290
10,600
10,915
11,225
11,535
11,850
12,160
12,475
12,785
13,095
13,405
13,720
14,030
14,345
14,655
14,965
ft./lbs.
1,660
1,992
2,324
2,656
2,988
3,320
3,652
3,984
4,316
4,648
4,980
3,560
5,644
5,976
6,308
6,650
6,983
7,315
7,648
7,980
8,360
8,694
9,029
9,363
9,698
10,100
10,437
10,773
11,110
11,447
11,720
12,055
12,390
12,725
13,005
13,510
13,848
14,186
14,523
14,861
15,020
15,354
15,688
16,021
ft./lbs.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1,000
1,200
1,400
1,600
1,800
2,000
2,200
2,400
2,600
2,800
3,000
3,200
3,400
3,600
3,800
4,000
4,200
4,400
4,600
4,800
5,000
5,200
5,400
5,600
3,700
230
252
475
1,001
1,173
1,344
1,516
1,688
1,865
2,042
2,219
2,396
2,574
2,775
2,976
3,177
3,378
3,580
3,735
3,891
4,046
4,202
4,358
4,538
4,718
4,898
5,078
5,258
5,410
5,562
5,715
5,867
6,020
6,186
6,352
6,519
6,685
6,852
7,023
7,195
7,366
7,538
7,710
7,894
8,078
8,262
4,440
269
294
555
5,180
307
336
630
5,920
346
378
710
6,660
385
420
790
7,400
422
462
870
8,140
461
504
950
8,880
500
546
1,025
1,105
1,185
1,265
1,345
1,420
1,500
1,580
1,660
1,740
1,815
1,895
1,975
2,055
2,135
2,210
2,290
2,370
2,450
2,530
2,605
2,685
2,765
2,845
2,925
3,000
3,080
3,160
3,240
3,320
3,395
3,475
3,555
3,635
3,710
3,790
9,620
537
588
10,360
11,100
11,840
12,580
13,320
14,060
14,800
15,540
16,280
17,020
17,760
18,500
19,240
19,980
20,720
578
640
614
681
653
724
691
766
730
809
771
855
806
894
845
937
883
980
922
1,022
1,070
1,112
1,155
1,198
1,241
1,285
1,327
1,370
1,412
1,455
1,500
1,541
1,583
1,626
1,669
1,715
1,755
1,798
1,840
1,883
1,929
1,969
2,011
2,054
964
998
1,037
1,075
5,800
6,000
6,200
6,400
6,600
6,800
7,000
7,200
7,400
7,600
7,800
8,000
8,200
8,400
8,600
8,800
9,000
9,200
9,400
9,600
1,114
1,156
1,190
1,229
1,267
1,305
1,349
1,382
1,421
1,460
1,497
1,542
1,574
1,613
1,651
1,690
1,735
1,766
1,805
1,843
21,460
22,200
22,940
23,680
24,420
25,160
25,900
26,640
27,380
28,120
28,860
29,600
30,340
31,080
31,820
32,560
33,300
34,040
34,780
35,520
9,800
1,882
1,928
2,097
2,145
3,870
3,950
8,446
8,630
15,280
15,595
16,355
16,600
N/A
N/A
36,260
37,000
10,000
- 5 -
TX-2, TX-4, TX-8 SERIES LINK
TX-16, TX-32 SERIES LINK
- 6 -
Part Numbers for Ordering (LINKS)
TX2
Part
TX4
TX8
TX16
TX32
SIDE PLATE - L
SIDE PLATE - R
DRIVE PLATE
DRIVE PIN
TX-2-L01 TX-4-L01 TX-8-L01 TX-16-L01 TX-32-L01
TX-2-L02 TX-4-L02 TX-8-L02 TX-16-L02 TX-32-L02
TX-2-L03 TX-4-L03 TX-8-L03 TX-16-L03 TX-32-L03
TX-2-L05 TX-4-L05 TX-8-L05 TX-16-L05 TX-32-L05
TX-2-L07 TX-4-L07 TX-8-L07 TX-16-L07 TX-32-L07
TX-2-L09 TX-4-L09 TX-8-L09 TX-16-L09 TX-32-L09
TX-2-L11 TX-4-L11 TX-8-L11 TX-16-L11 TX-32-L11
TX-2-L13 TX-4-L13 TX-8-L13 TX-16-L13 TX-32-L13
1
2
3
4
5
6
7
8
DRIVE PIN SPRING
RATCHET
DRIVE SEGMENT
UPPER SPACER
MIDDLE SPACER
N/A
N/A
N/A
TX-16-L14 TX-32-L14
9
LOWER SPACER
TX-2-L15 TX-4-L15 TX-8-L15 TX-16-L15 TX-32-L15
TX-2-L17 TX-4-L17 TX-8-L17 TX-16-L17 TX-32-L17
TX-2-L19 TX-4-L19 TX-8-L19 TX-16-L19 TX-32-L19
TX-2-L21 TX-4-L21 TX-8-L21 TX-16-L21 TX-32-L21
TX-2-L25 TX-4-L25 TX-8-L25 TX-16-L25 TX-32-L25
TX-2-L27 TX-4-L27 TX-8-L27 TX-16-L27 TX-32-L27
TX-2-L29 TX-4-L29 TX-8-L29 TX-16-L29 TX-32-L29
TX-2-L31 TX-4-L31 TX-8-L31 TX-16-L31 TX-32-L31
TX-2-L33 TX-4-L33 TX-8-L33 TX-16-L33 TX-32-L33
10
11
12
13
14
15
16
17
18
LOWER SPACER PIN
SLEEVES - SIDEPLATE
SHROUD
SEGMENT SPRING
SCREWS - UPPER SPACER
SCREWS - LOWER SPACER
SHROUD SCREWS
DRIVE PIN SPRING ROLL PIN
SPACER ROLL PIN
N/A
N/A
N/A
TX-16-35 TX-32-L35
19
- 7 -
- 8 -
Part Numbers for Ordering (CYLINDERS)
TX2
Part
TX4
TX8
TX16
TX32
HOUSING
TX-2-C01
TX-2-C03
TX-2-C03-1
N/A
TX-4-C01
TX-4-C03
N/A
TX-8-C01
TX-8-C03
N/A
TX-16-C01
TX-16-C03
TX-32-C01
TX-32-C03
1
PISTON ROD ASSEMBLY
PISTON ROD
TX-16-C03-1 TX-32-C03-1
TX-16-C03-2 TX-32-C03-2
TX-16-C03-3 TX-32-C03-3
TX-16-C03-4 TX-32-C03-4
TX-16-C03-5 TX-32-C03-5
2
3
PISTON CAP
N/A
N/A
VALVE BALL
N/A
N/A
N/A
VALVE SPRING
VALVE HOLLOW LOCK
PISTON SEAL PLATE
SEAL RING
N/A
N/A
N/A
N/A
N/A
N/A
TX-2-C05
TX-2-C07
TX-2-C09
TX-2-C11
TX-2-C13
TX-2-C15
TX-2-C17
TX-2-C21
TX-2-C23
TX-2-C25
TX-2-C27
TX-2-C29
TX-2-C31
TX-2-C33
N/A
TX-4-C05
TX-4-C07
TX-4-C09
TX-4-C11
TX-4-C13
TX-4-C15
TX-4-C17
TX-4-C21
TX-4-C23
TX-4-C25
TX-4-C27
TX-4-C29
TX-4-C31
TX-4-C33
TX-8-C05
TX-8-C07
TX-8-X09
TX-8-C11
TX-8-C13
TX-8-C15
N/A
N/A
N/A
N/A
4
N/A
5
SLIDER
TX-16-C09
TX-16-C11
N/A
TX-32-C09
TX-32-C11
N/A
6
END CAP
7
RETAINING RING
LINK PIN
8
TX-16-C15
N/A
TX-32-C15
N/A
9
END COVER
10
11
12
13
14
15
16
17
18
18
19
20
RETAINING SCREWS
END COVER SCREWS
BALL PLUNGER
SLIDER PIN
TX-8-C21
N/A
N/A
N/A
N/A
N/A
TX-8-C25
TX-8-C27
TX-8-C29
TX-8-C31
TX-8-C33
TX-16-C25
TX-16-C27
TX-16-C29
TX-16-C31
TX-16-C33
TX-32-C25
TX-32-C27
TX-32-C29
TX-32-C31
TX-32-C33
END PLUG SEAL
ROD SEAL
PISTON O-RING
SWIVEL SET
STX-4M-4M STX-4M-4M STX-4M-4M STX-4M-4M
SWIVEL SET
STX-4M-8M
HC-S100
TX-2-ST
N/A
HC-S100
TX-4-ST
N/A
N/A
HC-S100
TX-8-ST
N/A
N/A
HC-S100
N/A
N/A
HC-S100
N/A
COUPLER ASSEMBLY
SEAL INSERTION TOOL
END PLUG WRENCH
N/A
TX-16-EPW TX-32-EPW
21
- 9 -
Maintenance Section
NOTICE
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
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.
Always turn off the power supply, bleed off hydraulic
fluid from the hose connections on the cylinder
assembly and disconnect the hoses before attempting
to repair or perform maintenance on this tool.
Always wear eye protection when operating or
performing maintenance on this tool.
7. Thread one of the Swivel Inlets or a threaded pipe
with a tee into the End Cap (7). Use the Inlet or tee as
a handle to pull the End Cap and End Plug Seal (15)
out of the Housing through the Seal Insertion Tool.
8. Push the Piston Rod toward the inlet end of the
Housing and using a hex wrench, unscrew and remove
the two Retaining Screws (11).
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 a 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.
9. Insert a hooked tool through each screw hole in the
Piston Seal Plate (4) and work the Plate upward out of
the Housing.
10. Using an o-ring pick, pull the Seal Ring (5) and
Piston O-ring (17) off of the Piston Rod.
11. Push the piston end of the Piston Rod forward in the
Housing until the Slider Pin (14) aligns with the
cross holes in the Housing.
12. Using a small drift, tap the Slider Pin out of the
Sliders (5) and position shaft and remove the two
Sliders.
13. Push the piston out of the Housing.
14. If the Rod Seal (16) needs replacement, use a
hooked tool to pull it out of the Housing.
6. Use only British Standard fractional size tools when
disassembling these tools.
Disassembly of the TX-16 and TX-32 Cylinder
Assemblies
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 Plats and
separate the two units.
1. Grasp the Housing (1) in copper-covered or leather-
covered vise jaws with the inlet end upward and using
a ¾” wrench, unscrew and remove the two Swivel
Inlets (18) with their attached Couplers (19).
2. Remove the housing assembly from the vise jaws and
over a container to catch the oil, move the Piston Rod
Assembly (2 & 3) back and forth several times to
purge the hydraulic oil from the Housing.
Disassembly of the TX-2, TX-4, and TX-8 Cylinder
Assemblies
1. Grasp the Housing (1) in copper-covered or leather-
covered vise jaws with the inlet end upward and using
a ¾” wrench, unscrew and remove the two Swivel
Inlets (18) with their attached Couplers (19).
2. Remove the Housing Assembly from the vise jaws and
over a container to catch the oil, move the Piston Rod
(2) back and forth several times to purge the hydraulic
oil from the Housing.
3. Grasp the Housing in copper-covered or leather-
covered vise jaws with the inlet end upward.
4. Insert the pins of the End Plug Wrench (21) into the
holes of the End Cap (7). Using a wrench on the hex
of the End Plug Wrench, unscrew and remove the End
Cap with the End Plug Seal (15).
5. Push the Piston Rod far enough into the Housing to
expose the hex on the piston head.
3. Grasp the Housing in copper-covered or leather-
covered vise jaws with the inlet end upward.
4. For TX-2 and TX-4 models, use a hex wrench to
unscrew and remove the End Cover Screw (12).
Remove the End Cover (14).
NOTICE
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 surface. Any nicks
or scratches to the surface will allow hydraulic oil to
leak from the Cylinder when the tool is reassembled.
5. Push the End Cap (7) inward approximately ½” and
remove the two Retaining Rings (8) by working them
out of the groove in the Cylinder.
6. Install the Seal Insertion Tool (20) on the inlet end of
the Housing.
6. Sprag the flat end of the piston shaft against rotation
and using a socket on the hex of the piston head,
- 10 -
unscrew and remove the piston head from the shaft
with the Piston O-ring (17).
ASSEMBLY
General Instructions
1. Use extra care not to score, nick or damage surfaces
that will contain hydraulic oil under pressure.
2. 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 if threaded members and housings.
3. Apply o-ring lubricant to all o-rings before final
assembly.
7. Pull the Piston shaft out of the Housing.
8. If the Sliders (5) must be replaced, 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
shaft.
9. If the Rod Seal (16) needs replacement, use a hooked
tool to pull it out of the 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).
2. Using a hex wrench, unscrew and remove the two
Upper Spacer Screws (15).
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 the shoulder of the Sleeves enters
the recesses in the Side Plates and are pressed flush
with the faces.
3. For Series TX-16 and TX-32, 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.
2.For Series TX-2, TX-4, and TX-8, position the
Middle Spacer (9) 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 and TX-32,
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), and 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.
5. Grasp the Ratchet and Drive Plate (3) and, while
maintaining their relationship, lift them both off the
Left Side Plate.
NOTICE
In the following step, 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 not allow the Drive Segment to fall on a hard
surface that might chip the teeth.
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.
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.
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.
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.
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.
9. For Series TX-2, TX-4, and TX-8, unscrew the two
Spacer Screws and remove the Middle Spacer (9) from
the Right Side Plate. For Series TX-16 and TX-32,
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.
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.
- 11 -
9. Wrap the threads of the Swivel Sets (18) with Teflon
tape and thread the swivel with the male hose Coupler
(19) into the center of the End Cap. Thread the Swivel
with the female Coupler into the hole in the Housing
directly above the End Cap.
NOTICE
In the following step, an excessive amount of
grease will prevent proper tooth engagement
between the Ratchet and the Drive Segment
causing the tool to malfunction.
Assembly of the TX-2, TX-4, and TX-8 Cylinder
Assemblies
7.Wipe a thin film of Marine Grade Moly Lube onto the
inner race of the large opening in the Drive Plate.
8.Position the Ratchet (6) in the central opening of the
Drive Plate.
1. Grasp the link retaining pin lug in copper-covered,
vise jaws with the Housing (1) horizontal.
2. If the Rod Seal (16) was removed from the Housing,
apply a coat of o-ring lubricant to the Seal and install
it, lip end trailing, in the recess at the bottom of the
piston bore.
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.
3. Press the Slider Pin (14) into one of the Sliders (5)
flush with one side. Install the Pin through the hole in
the piston shaft and press the remaining Slider onto
the Pin.
4. Install the Piston O-ring (17) in the grooves of the
piston head.
11. Apply a light coat of Marine Grade Moly Lube to
both sides of the Drive Plate and Drive Segment.
Apply some of the Moly Lube to 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.
5. Insert the piston rod, threaded end leading, into the
small central opening from the non-piston end of the
Housing. The notch in the trailing end of the shaft
should be toward the Ball Plunger (13).
6. Insert the piston, hex end trailing, into the bore of the
Housing, and use socket to thread and tighten the
piston onto the piston shaft.
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.
7. Install the End Plug Seal (15) in the groove on the hub
of the End Cap (7).
8. Using the End Plug Wrench (21), thread the
assembled End Cap, o-ring end leading, into the piston
end of the Housing and tighten it.
9. Wrap the threads of the Swivel Sets (18) with Teflon
tape and thread the swivel with the male hose Coupler
(19) into the center of the End Cap. Thread the Swivel
with the female Coupler into the hole in the Housing
directly above the End Cap.
Assembly of the TX-16 and TX-32 Cylinder
Assemblies
1. Grasp the link retaining pin lug in copper-covered,
vise jaws with the Housing (1) horizontal.
2. If the Rod Seal (16) was removed from the Housing,
apply a coat of o-ring lubricant to the Seal and install
it, lip end trailing, in the recess at the bottom of the
piston bore.
3. Press the Slider Pin (14) into one of the Sliders (5)
flush with one side. Install the Pin through the hole in
the piston shaft and press the remaining Slider onto
the Pin.
Assembly of the TX-2, TX-4, and TX-8 Cylinder
Assemblies
1. Grasp the link retaining pin lug in copper-covered vise
jaws with the Housing (1) horizontal.
2. If the Rod Seal (16) was removed from the Housing,
apply a coat of o-ring lubricant to the Seal sand install
it, lip end trailing, in the recess at the bottom of the
piston bore.
4. Install the Piston O-ring (17) in the groove of the
piston head.
3. Insert the piston rod, notched end leading, into the
Rod Seal and the small central opening from the
piston end of the Housing. The notch in the leading
end of the shaft should be toward the Ball Plunger
(13).
5. Insert the piston rod, threaded end leading, into the
small central opening from the non-piston end of the
Housing. The notch in the trailing end of the shaft
should be toward the Ball Plunger (13).
6. Insert the piston, hex end trailing, into the bore of the
Housing, and use socket to thread and tighten the
piston onto the piston shaft.
4. Push the Piston Rod (2) inward until the hole for the
Slider Pin (14) aligns with the holes in the walls of the
Housing.
7. Install the End Plug Seal (15) in the groove on the hub
of the End Cap (7).
5. Position one Slider (6) on each side of the piston shaft
and insert the Slider Pin through the hole in the
Housing into both Sliders and the piston shaft. The fit
between the Pin and Sliders is an interference fit. Use
a brass hammer and drift to set the Slider Pin below
8. Using the End Plug Wrench (21), thread the
assembled End Cap, o-ring end leading, into the piston
end of the Housing and tighten it.
- 12 -
the outer edge of both Sliders or deep enough to
prevent the shaft ends from dragging on the Housing
walls.
6. Install the Piston O-ring (17) in the internal groove of
the Seal Ring (5).
14. Install the Retaining Rings (8) in the housing
grooves at the inlet end of the Housing. Install the
Rings with the open ends of both rings at the middle
of the opening and the beveled side of the Rings
toward the End Cap.
7. Install the assembled Seal Ring and Piston O-ring on
the hub at the large end of the Piston Rod.
8. Install the Piston Seal Plate (4) in the inlet end of the
Housing with the side having the countersunk screw
holes trailing.
15. If an air hose is available, inject some air into the
threaded opening of the End Cap to seat the Retaining
Rings. If air is not available, temporarily thread one of
the Swivel Sets (18) into the threaded opening and
pull the End Cap back against the Retaining Rings to
seat them.
NOTICE
16. For TX-2 and TX-4 models position the End
Cover (10) against the Housing and after applying a
non-permanent thread-locking compound to the
threads, install the End Cover Screw (12).
17. Wrap the threads of the Swivel Sets (18) with
Teflon tape and thread the swivel with the male hose
Coupler (19) into the threaded hole in the End Cap.
18. Apply some Marine Grade Moly Lube to the notch
in the Piston Rod and the face of the Sliders.
In the following step, DO NOT use thread-locking
compound on the screw threads.
9. Using a hex wrench and an alternating tightening
procedure, install the Retaining Screws (11). Tighten
each Screw a little at a time to obtain even
compression and expansion of the Piston O-ring and
Seal Ring.
10. Place the Seal Insertion Tool (20) on the inlet end of
the Housing.
Assembly of the Tool
11. Install the End Plug Seal (15) in the groove of the
End Cap (7)
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 (2) 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 Ball Plunger (13) snaps into the annular
groove around the center of the Link Pin.
12. Insert the assembled End Cap into the Housing
through the Tool with the O-ring end leading and the
threaded inlet hole downward. Push the Cap inward
beyond the Retaining Ring groove and approximately
½” into the Cylinder.
13. Remove the Seal Insertion Tool from the Housing.
- 13 -
Troubleshooting Guide
Probable Cause
Trouble
Solution
Couplers are not securely attached to
the tool or pump
Check the Coupler connections and make
certain that they are connected.
Piston will not advance or
retract
Coupler is defective
Replace any defective Coupler.
Defective remote control switch
Dirt in the direction-control valve of
the pump unit
Replace the switch and/or control pendent
Disassemble the pump and clean the
direction-control valve.
Make certain the advance on the pump is
connected to the advance on the tool and
retract on the pump is connected to the
retract on the tool.
Hose connections reversed
Piston will not retract
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
leaking
Replace any defective O-rings
Cylinder will not build up
pressure
Retaining Screws sheared
Coupler is defective
Replace any broken screws.
Replace any defective Coupler
Grease or dirt build up in the teeth of
the Ratchet and Segment Pawl
Worn or broken teeth on Ratchet an/or
Segment Pawl
Disassemble the Ratchet and clean the
grease or dirt out of the teeth
Ratchet will not turn
Replace any worn or damaged parts
Depress the advance button to release the
tool; shut the pump off in the advance
position and reverse the hose connection
Inspect, adjust or replace the relief valve
Make certain the air supply and hose size
Tool tightens immediately
when turned on
Hose connections are reversed
Defective relief valve
Air supply too low or air hose too small comply with the pump manual
recommendations.
Make certain the amperage, voltage and
Pump will not build up
pressure
Electric power source is too low
any extension cord size comply with the
pump manual requirements
Defective Gauge
Low oil level
Replace the Gauge
Check and fill the pump reservoir
Inspect, clean and/or replace the pump
filter
Clogged filter
Pressure reading erratic
Defective Gauge
Replace the Gauge
Nut Returns with retract
stroke
Ball Plungers are not engaging the
Drive Sleeves
Thread the Ball Plungers to the correct
depth in the Housing.
NOTICE
SAVE THESE INSTRUCTIONS. DO NOT DESTROY.
- 14 -
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