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RSL Tools Operation and Maintenance Manual: Hex Wrench Square Drive Wrench SET SET
RSL Tools Operation and Maintenance Manual: Hex Wrench Square Drive Wrench SET SET
RSL TOOLS
Operation and Maintenance
Manual
TABLE OF CONTENTS
SECTION Page
1 SAFETY 3
1.0 - RSL TOOL SAFETY 3-4
1.1 – GENERAL SAFETY 4
1.2 – RSL TOOL SAFETY – PUMP TAG 5
2 SPECIFICATIONS 6
2.0 - SQUARE DRIVE (SQ. DR.) TOOLS 6
2.1 – HEX BITS FOR SQUARE DRIVE TOOLS 7
2.2 – HEX WRENCH 8-9
2.3 – NOMINAL OUTPUT TORQUE VS. PRESSURE TABLE 10
3 WRENCH DESCRIPTION 11
4 RSL TERMS & BOLTING CALCULATIONS 11-14
5 PLANNNING 14-16
6 OPERATING INSTRUCTIONS 16
6.0 – FLANGE ASSEMBLY & DISASSEMBLY 16
6.1.0 – CHOOSE FLANGE ASSEMBLY METHOD 16
6.1.1 – FLANGE DISASSEMBLY (LOOSEN) 16
6.1.2 – FLANGE ASSEMBLY EXAMPLE 17
6.2 – HEX TOOL REACTION 17-18
6.3 – SQUARE DRIVE TOOL REACTION 18-20
6.4 – OPERATING INSTRUCTIONS 20-22
7 WARRANTY, MAINTENANCE, & ASSEMBLY 22
7.1 – WARRANTY 22
7.2 – POWER HEAD MAINTENANCE 22
7.3 – POWER HEAD ASSEMBLY, TESTING, & DISASSEMBLY 22-23
7.4 – HEX & SQUARE DRIVE WRENCH MAINTENANCE 23
8 TROUBLE SHOOTING 24
8.0 – TABLE 24
8.1 – GENERAL HYDRAULIC 25
9 PART NUMBERS AND DRAWINGS 26
9.0 – POWER HEAD 26-27
9.0 – HEX WRENCH 28
9.0 – SQ. DR. WRENCH 29
9.0 – REACTION ARM 30
9.0 – SEAL KITS 31
10 TORQUE, FLANGE, & BOLT REFERENCE 32-37
11 TOOL ACCESSORIES 37
12 NOTES 38-39
WARRANTY 40
This tool, when used in conjunction with specified pump and hoses, conforms to
requirements for CE Marking. Contact Hydratight for a list of approved
components.
Operator must read, understand, and comply with all operating instructions prior to and during RSL
operation! Failure to do so may result in severe or fatal injury.
Hydratight highly recommends that one properly trained person hold and control operation of tool.
When two-person operation cannot be avoided:
A risk assessment must be performed that fully addresses specific application, communication, and
coordination of tool operation between two users.
Person HOLDING wrench must control operations and give command to energize pump.
Tool is a potential fall hazard when used overhead. To avoid a fall hazard:
Securely tie tool off to a fixed object, and (as needed) secure socket to square drive with pin and ring.
Securely attach reaction arm to power head with reaction arm’s locking device (e.g. dialock).
Operator’s hazard analysis may determine that reaction arm must be further retained. Contact
Hydratight for Bulletin 116, which shows how to properly tie reaction arm to power head with a cable.
Protect yourself against a fall. Use proper equipment & follow proper procedures when working at
height.
Do not use tool while tired or under the influence of drugs, alcohol, or medication.
Work site:
o Keep work site clean.
o Maintain adequate work space.
o Clear area of flammable substances.
Keep loose clothing, long hair, or any other unsecured parts away from operating machines.
If a power failure occurs, set control valves and switches to proper position.
Valves are typically “closed” and switches are typically “off”.
INCORRECT REACTING
WILL CAUSE HIGH STRESS
ON TOOL AND SOCKET,
MAY RESULT IN POSSIBLE
BREAKAGE AND INJURY
COCKING
HIGH HYDRAULIC
AVOID ANY
USE WITH PROPER ANGULAR
690 BAR ENGAGEMENT
10000 PSI TOOLS AND HOSES
NO ANGULAR
ADJUSTMENT
ALLOWED.
90° IN LINE
REACTION
ONLY
RSL-STAG-REV A
SIDE 1 SIDE 2
TABLE 2.0-1
Square Drive Dimensions and Specifications
Weight
Square
Square Max Output
Drive W W1 H L L1 R Reaction Sq. Dr.
Drive Torque Power Head
Size Arm Head
Model
lb-ft N-m in in mm in mm in mm in mm in mm in mm lb kg lb kg lb kg
RSL2 1408 1909 0.75 1.25 32 2.30 58 4.48 114 6.29 160 7.45 189 0.94 24 3.4 1.55 1.0 0.45 2.8 1.27
RSL4 3080 4176 1.00 1.50 38 2.88 73 5.57 141 7.67 195 10.3 262 1.25 32 5.6 2.55 2.2 1.00 5.2 2.36
RSL6 5303 7190 1.50 1.75 45 3.71 94 6.42 163 9.27 235 11.67 296 1.52 39 8.9 4.05 4.0 1.81 9.1 4.14
RSL8 7862 10659 1.50 2.40 61 4.14 105 6.65 169 9.47 241 11.78 300 1.52 39 10.6 4.82 4.3 1.95 11.6 5.27
RSL14 11154 15123 1.50 2.50 64 4.63 118 7.93 201 11.2 284 12.4 315 1.88 48 11.6 5.27 6.6 3.00 18.4 8.36
RSL20 18843 25547 2.50 3.25 83 6.38 162 9.48 241 13.46 342 18.97 482 2.5 64 20.0 9.09 15.7 7.12 28.9 13.14
RSL30 28002 37965 2.50 3.50 89 6.54 166 10.35 263 14.09 358 21.07 536 2.5 64 22.0 10.00 11.1 5.03 39.3 17.86
TABLE 2.2-1
Hex Wrench Dimensions and Specifications
Hex Max Torque
Max. AF Size R L W H
Wrench Output
Model & inch inch
Housing mm lb-ft N-m inch mm inch mm inch mm inch mm
(decimal) (fraction)
RSL2H014 0.875 7/8 22 320 433.9 0.79 20.1 6.00 152.4 1.25 31.8 4.33 110
101 1.062 1 1/16 27 640 867.7 0.95 24.1 6.05 153.7 1.25 31.8 4.50 114.3
104 1.250 1 1/4 31 640 867.7 1.03 26.2 6.12 155.4 1.25 31.8 4.57 116.1
107 1.438 1 7/16 36 900 1220.2 1.15 29.2 6.24 158.5 1.25 31.8 4.69 119.1
110 1.625 1 5/8 42 1408 1909 1.31 33.4 6.41 162.8 1.25 31.8 4.86 123.4
113 1.813 1 13/16 46 1408 1909 1.40 35.5 6.49 164.8 1.25 31.8 4.94 125.5
200 2.000 2 50 1408 1909 1.48 37.7 6.58 167.1 1.25 31.8 5.03 127.8
203 2.188 2 3/16 55 1408 1909 1.58 40.1 6.68 169.7 1.25 31.8 5.13 130.3
206 2.375 2 3/8 60 1408 1909 1.70 43.2 6.79 172.5 1.25 31.8 5.24 133.1
RSL4H104 1.250 1 1/4 32 600 813.5 1.03 26.2 7.45 189.2 1.38 35.1 5.35 135.9
107 1.438 1 7/16 36 900 1220.2 1.18 30 7.62 193.5 1.38 35.1 5.49 139.4
110 1.625 1 5/8 41 1200 1627 1.32 33.5 7.77 197.4 1.38 35.1 5.63 143
113 1.813 1 13/16 46 1900 2576 1.47 37.3 7.87 199.9 1.38 35.1 5.78 146.8
200 2.000 2 50 2600 3525.1 1.60 40.6 8.04 204.2 1.38 35.1 5.92 150.4
203 2.188 2 3/16 55 3080 4175.9 1.76 44.7 8.16 207.3 1.38 35.1 6.08 154.4
206 2.375 2 3/8 60 3080 4175.9 1.84 46.7 8.25 209.6 1.38 35.1 6.15 156.2
209 2.562 2 9/16 65 3080 4175.9 1.95 49.5 8.14 206.8 1.38 35.1 6.26 159
212 2.750 2 3/4 70 3080 4175.9 2.04 51.8 8.23 209 1.38 35.1 6.36 161.5
215 2.938 2 15/16 74 3080 4175.9 2.16 54.9 8.34 211.8 1.38 35.1 6.54 166.1
RSL6H200 2.000 2 50 2600 3525.1 1.61 40.9 9.08 230.6 1.75 44.5 6.52 165.6
203 2.188 2 3/16 55 3500 4745.3 1.71 43.4 9.18 233.2 1.75 44.5 6.62 168.1
206 2.375 2 3/8 60 4500 6101.1 1.87 47.5 9.34 237.2 1.75 44.5 6.78 172.2
209 2.562 2 9/16 65 5303 7189.8 2.01 51.1 9.48 240.8 1.75 44.5 6.92 175.8
212 2.750 2 3/4 70 5303 7189.8 2.16 54.9 9.63 244.6 1.75 44.5 7.07 179.6
215 2.938 2 15/16 75 5303 7189.8 2.24 56.9 9.71 246.6 1.75 44.5 7.15 181.6
302 3.125 3 1/8 80 5303 7189.8 2.26 57.4 9.73 247.1 1.75 44.5 7.17 182.1
TABLE 2.2-2
Hex Wrench Dimensions and Specifications
Hex Max. Output
Max. AF Size R L W H
Wrench Torque
Model & in. in.
Housing mm lb-ft N-m in. mm in. mm in. mm in. mm
(decimal) (fraction)
RSL8H203 2.188 2 3/16 55 3500 4745.3 1.71 43.4 9.37 238.0 2.25 57.2 6.84 173.7
206 2.375 2 3/8 60 4500 6101.1 1.87 47.5 9.53 242.1 2.25 57.2 7.00 177.8
209 2.562 2 9/16 65 5800 7863.6 2.10 53.3 9.67 245.6 2.25 57.2 7.13 181.1
212 2.750 2 3/4 70 7862 10659.3 2.16 54.9 9.82 249.4 2.25 57.2 7.28 184.9
215 2.938 2 15/16 75 7862 10659.3 2.24 56.9 9.90 251.5 2.25 57.2 7.36 186.9
302 3.125 3 1/8 - 7862 10659.3 2.26 57.4 9.92 252.0 2.25 57.2 7.39 187.7
302 - - 80 7300 9897.3 2.26 57.4 9.92 252.0 2.25 57.2 7.39 187.7
RSL14H209 2.562 2 9/16 65 5800 7863.6 1.98 50.3 10.00 254.0 2.50 63.5 8.03 204.0
212 2.750 2 3/4 70 7300 9897.3 2.19 55.6 11.20 284.5 2.50 63.5 8.23 209.0
215 2.938 2 15/16 75 9000 12202.2 2.29 58.2 11.31 287.3 2.50 63.5 8.34 211.8
302 3.125 3 1/8 79 11154 15122.6 2.43 61.7 11.44 290.6 2.50 63.5 8.47 215.1
308 3.500 3 1/2 89 11154 15122.6 2.60 66.0 11.71 297.4 2.50 63.5 8.64 219.5
314 3.875 3 7/8 98 11154 15122.6 2.88 73.2 11.89 302.0 2.50 63.5 8.92 226.6
404 4.250 4 1/4 108 11154 15122.6 2.98 75.7 12.00 304.8 2.50 63.5 9.03 229.4
410 4.625 4 5/8 117 11154 15122.6 3.25 82.6 12.27 311.7 2.50 63.5 9.30 236.2
RSL20H302 3.125 3 1/8 79 11000 14913.8 2.45 62.2 12.72 323.1 2.75 69.9 9.44 239.8
308 3.500 3 1/2 89 16000 21692.8 2.77 70.4 13.04 331.2 2.75 69.9 9.76 247.9
314 3.875 3 7/8 98 18843 25547.3 2.95 74.9 13.22 335.8 2.75 69.9 9.94 252.5
404 4.250 4 1/4 108 18843 25547.3 3.30 83.8 13.57 344.7 2.75 69.9 10.28 261.1
410 4.625 4 5/8 117 18843 25547.3 3.44 87.4 13.71 348.2 2.75 69.9 10.43 264.9
RSL30H308 3.500 3 1/2 89 16000 21692.8 2.56 65.0 14.36 364.7 3.00 76.2 10.54 267.7
314 3.875 3 7/8 98 22000 29827.6 2.92 74.2 14.36 364.7 3.00 76.2 10.77 273.6
404 4.250 4 1/4 108 28002 37965.1 3.29 83.6 14.47 367.5 3.00 76.2 11.14 283.0
410 4.625 4 5/8 117 28002 37965.1 3.43 87.1 14.61 371.1 3.00 76.2 11.28 286.5
500 5.000 5 127 28002 37965.1 3.65 92.7 14.83 376.7 3.00 76.2 11.50 292.1
506 5.375 5 3/8 136 28002 37965.1 3.79 96.3 14.97 380.2 3.00 76.2 11.64 295.7
512 5.750 5 3/4 146 28002 37965.1 4.05 102.9 15.23 386.8 3.00 76.2 11.90 302.3
602 6.125 6 1/8 155 28002 37965.1 4.22 107.2 15.48 393.2 3.00 76.2 12.15 308.6
TABLE 2.3-1
Caution!
1. Do not modify any equipment or
accessories.
2. Contact HYDRATIGHT for special
applications or modifications.
3. Unauthorized modifications may
cause injury and/or damage plus
invalidate warranty.
Swivels – Square Drive Wrench
Low Pressure
Retract Stroke
High Pressure
Advance Stroke
Low Pressure
Retract Stroke
High Pressure
Advance Stroke
Square Drive
Hex Bit
QD’s for Power Head Hoses
(Male Hex Insert)
Screw Type w/ Relief Valve
Insert, Hex
Square Drive Wrench Set (SDS)
FIGURE 4.0–2 TERMS FIGURE 4.0–3 TERMS
1.3
Ar .7854 * Db ^2
ƒt = Friction coefficient – threads. n
ƒn = Friction coefficient – nut face. ----------------------------------------------------------------
Db = Nominal stud (bolt) diameter (in.).
Dmin = Minimum pitch diameter (in.)
n = Threads per inch
SECTION 6.1.0
SECTION 5.0 - PLANNING (cont.) CHOOSE FLANGE ASSEMBLY METHOD
1. TIGHTEN METHOD 1 – Follow equipment
manufacturer procedures
2. TIGHTEN METHOD 2 – Torque, Legacy Cross-
Pattern Tightening Sequence & Bolt Numbering,
Single tool 8 bolt flange example - Fig. 6.1.2-1:
a. Mark fasteners with chalk in clockwise direction
(1, 2, 3, 4, 5, 6, 7, & 8). These numbers are
outside large circle in Fig. 6.1.2-1 and
correspond to numbers in examples below
(e.g. 1-5-3-7-2-6-4-8).
b. Mark correct tightening sequence on studs
(“1”, “2”, “3”, “4”, “5”, “6”, “7”, & 8”).
i. This sequence is defined by example below
FIG. 5.0-1 - Square Drive Tool (e.g. 1-5-3-7-2-6-4-8).
ii. These are “circled numbers” in Fig 6.1.2-1.
iii. In this case “1” relates to 1, “2” to 5, “3” to 3,
“4” to 7, “5” to 2, “6” to 6, “7” to 4, & “8” to 8.
c. Determine torque value for each stage of stud
tightening (Section 5.0- 6 & 4.0-10)
i. First stage - limit to 30% of final torque.
ii. Second stage - limit to 60% of final torque.
iii. Third & Fourth stages - 100% of final torque.
d. Tighten sequence:
i. First, second & third stages: Cross-pattern
tighten sequence in Fig. 6.1.2-1 (b).
ii. Fourth, and Final Stage:
1) Clockwise “adjacent bolt-to-bolt
tightening” Fig. 6.1.2-1 (c).
2) Continue until all nuts stop rotating.
28 Bolt Flange 1-13-21-5-17-9-25-3-15-23-7-19-11-27-2- 8. Figure 6.2-5 (top) shows a common reaction method. RSL
14-22-6-18-10-26-4-16-24-8-20-12-28 reacts on power head housing’s flat surface.
32 Bolt Flange 1-17-9-25-5-21-13-25-3-19-11-31-7-29-15- Warning! Do not react against power head splines
27-2-18-10-30-6-22-14-26-4-20-12-32-8-24- (Fig. 6.2-5 (bottom)). Use spline cover (RSLxx-700S)
16-28 to prevent damage.
9. “Bump Reaction”:
a. Figure 6.2-3 shows a proper “Bump Reaction”.
b. Most hex wrenches do not have reaction bumps.
c. Figure 6.2-4 shows a hex wrench without a “Bump” &
shows an improper reaction.
st nd rd
(a) Marked up (b) 1 , 2 , and 3 Stage
8 Bolt Flange Cross-Pattern Sequence
FIGURE 6.2-1
FIGURE 6.1.2-1 PROPER REACTION FOR HEX TOOL WITH
LEGACY CROSS-PATTERN TIGHTENING REACTION ARM
SEQUENCE FOR 8 BOLT CIRCULAR FLANGE (Reaction arm must be as shown)
PROPER REACTION
FIGURE 6.2-2
HEX TOOL REACTION WITH REACTION ARM
IMPROPER REACTION
DO NOT REACT ON SPLINE
FIGURE 6.2-5
HEX TOOL REACTION -
NO REACTION ARM
(Tighten Position for RH Threads)
SECTION 6.3
SQUARE DRIVE TOOL REACTION
1. Determine if fastener is right hand or left hand thread
2. Determine if fastener will be loosened or tightened
FIGURE 6.2-3 a. Plan to place square drive (sq. dr.) wrench head on
PROPER HEX TOOL REACTION WITH nut for loosening (See figure 6.3-1 & 6.3-2).
b. Plan to place square drive (sq. dr.) wrench head on
REACTION “BUMP” nut for tightening (See figure 6.3-1 & 6.3-2).
3. Fig. 6.3-1 & 6.3-2 show proper sq. dr. tool reaction. Arrow
by hose points to gap required for proper reaction.
4. Figure 6.3-3 shows improper sq. dr. tool reaction
a. Improper reaction and/or incorrect socket size make
tool, socket, or nut vulnerable to fracture.
b. Sq. dr. tool must use reaction arm. Contact
Hydratight engineering for special applications.
c. Reaction arm should be at 90 degrees and extend in
same direction as sq. dr. If rotation is required,
rotation must not exceed 3 degrees. Angle in Fig.
6.3-1 (right) must be 87 to 90 degrees. If reaction
arm rotated more than 3 degrees:
i. Life may be reduced
ii. Components and/or socket may fracture
FIGURE 6.2-4 d. Lifting (cocking) is when a socket fits over bolt at an
IMPROPER HEX TOOL REACTION angle. It:
DO NOT REACT ON HEX WRENCH HOUSING i. Is a common cause of socket breakage
(NO REACTION BUMP) ii. May occur when reaction arm:
1) Has small engagement & operator lifts
reaction arm over flange. This creates “out of
square” engagement.
2) Reacts against sloped surface
FIGURE 6.3-4
STEEL REACTION ARM EXTENSIONS
Do Not Weld
FIGURE 6.3-5
DO NOT WELD TO REACTION ARMS LIKE THIS FIGURE 6.4-1
WRENCH & POWER HEAD ASSEMBLY
SECTION 6.4
OPERATING INSTRUCTIONS TABLE 6.4-1
1. Hydratight inspects all tools prior to shipment. However:
a. Inspect for tool damage, leaks, etc. before each use. Power Head Bolt Torque
b. Verify that all parts are included.
c. Do not use hoses as a handle or lift strap when Long Bolts Short Bolts
lifting or moving tool.
MODEL
2. Select proper tool and accessories (See section 5.0): Lb*ft N*m Lb*ft N*m
a. Torque rating
RSL2 19 26 23 31
b. RSLxxSDS - Square drive wrench & power head
i. Reaction arm, or other. RSL4 35 48 45 61
ii. Square drive AF (across flat) RSL6 60 82 105 142
iii. Male hex bit. Table 2.1-1 (for socket head cap RSL6A 85 116 105 142
screws) RSL8 170 231 210 285
iv. Socket (for hex head cap screws & nuts):
RSL14 110 149 110 149
1) Fastener AF
2) Short or long RSL20 90 122 90 122
c. RSLxxHxxx – Hex wrench and power head RSL30 150 203 150 203
i. Reaction arm, tube, sleeve, or other Notes:
ii. Proper hex insert 1. Use lubricant (oil)
3. (Hex Wrench) Change hex wrench insert for proper AF. 2. Similar bolts have different torque values
because required clamp loads vary
7. (As needed) Assemble reaction arm ass’y. to wrench. FIG. 6.4-3 - QD’s - THREADED TYPE
a. Rotate dialock to allow reaction arm to slide on to
power head splines. 10. Purge all air from tool before returning to service.
b. Slip reaction arm over power head splines until it Suggested method:
stops against o-ring. a. Connect Power Head to pump.
c. Rotate dialock (any direction) to next “click” (60 b. Place Power Head below pump
degrees), to lock reaction arm in place. c. Extend piston to end of stroke.
d. Check dialock engagement - pull reaction arm. d. Remove hoses from power head & connect
e. Warning! Dialock must be in locked position hoses together.
before using tool! e. Turn pump on and run for one minute.
f. (As needed) Secure reaction arm ass’y. to power f. Repeat until rod extends & retracts smoothly.
head with safety cable. Sect. 1.0 – RSL Safety. 11. Tighten or loosen fasteners in accordance with
instructions in Section 6.1.
8. Connect air or electrical power source to hydraulic a. TIGHTEN METHOD 1 - Follow equipment
pump. See pump manual. manufactures procedures.
b. TIGHTEN METHOD 2 - Torque - Legacy Cross-
9. Assemble twin hose to pump (1st) & tool (2nd) before Pattern Tightening Sequence & Bolt Numbering
setting tool on application. Fig. 6.4-(2/3/4) & 8.1-1. System – One Tool
a. Each end of a twin hose will have one male and c. TIGHTEN METHOD 3 – Stud Elongation
one female quick connect fitting (QD). d. TIGHTEN METHOD 4 – See Guidelines in
b. Pump will have like male/female fittings. Pressure Boundary Bolted Flange Joint Ass’y.
c. Connect pump high pressure advance stroke e. LOOSEN (BREAKOUT)
port to tool high pressure advance port. f. Note: Power Head, Square Drive Wrench Head,
d. Connect remaining low pressure ports. Socket & Reaction Arm can be moved as a unit.
e. Always use an odd number (1, 3, 5 …) of twin g. Note: Remember fasteners are typically
hose assemblies to connect tool to pump. tightened, or loosened, incrementally. e.g. All
f. CEJN QD assembly procedure (fig. 6.4-2): fasteners are loosened 1/8 turn in a first pass.
i. Unscrew locking collar on female QD. 12. Determine if fastener will be loosened or tightened.
ii. Slide outside slide ring back. Snap male and Set-up tool on proper nut according to the following:
female fittings together. a. Tighten right hand threads: Place tool on nut so
iii. Release slide ring. tool advance stroke will rotate nut clockwise.
iv. Screw locking collar back against slide ring. b. Loosen right hand threads: Place tool on nut so
tool advance stroke will rotate nut counter-
clockwise.
c. (As needed) Change square drive position to
Locking Collar loosen or tighten. See Section 6.4 – 5.
13. Reaction and tool leak check:
Slide Ring a. Check that reaction arm is in firm contact with
Female QD stationary object (e.g. nut, flange, or housing).
Low Pressure Retract b. For new applications:
i. Set pump pressure near zero to start.
ii. Gradually increase pressure and carefully
watch tool for proper reaction and oil leaks
Male QD 1) If tool reacts improperly (e.g. Lifts over
High Pressure Advance reaction point), re-do reaction setup
2) If tool leaks, repair leaks immediately
c. Set pressure to minimum required for
FIGURE 6.4 - 2 application to maximize tool life.
HOSE QD’s – CEJN TYPE
2. Check housing and all internal parts for cracks, chips, Inspect For
deformities, and wear. Cracks
a. Immediately replace parts which have cracks, chips,
deformities, or excessive wear FIGURE 7.3-1
b. Inspect: Square drive, square driver, pawl (fig. 7.3-1),
pawl driver, pawl holding spring(s), sq. dr. wrench PAWL INSPECTION
housing, hex wrench housing halves, fasteners, etc.
Pawl Teeth Must be in
3. Hex wrench disassembly: Precise Engagement
a. Remove socket head cap screw joining hex wrench with Square Driver or
housings. Hex Insert Teeth
b. Separate housing halves to expose ratcheting
assembly.
c. Inspect pawl teeth engagement (fig. 7.3-2): It is
extremely important that pawl & hex insert teeth
are in precise engagement.
4. Square drive wrench disassembly:
a. Remove sq. dr. from sq. dr. housing. Section 6.4-5.
b. Remove ratcheting assembly through bottom of
square drive housing.
c. Inspect pawl teeth engagement (fig. 7.3-2): It is
extremely important that pawl & square driver
teeth are in precise engagement.
FIGURE 7.3-2
PAWL TEETH ENGAGEMENT
SECTION 8.0
TROUBLE SHOOTING
TABLE 8.0-1
TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
Hydraulic fluid leaks from power head. Power head seals are worn. Replace power head seals
- Power head rod does not extend, or 1. Quick connect couplings are: 1. Clean & properly connect
retract. a. Improperly assembled. couplings. Use pliers to tighten
- Pump gauge shows hydraulic b. Worn & not properly engaged. screw-on type.
pressure. 2. Piston seal is worn & hydraulic 2. Replace worn couplings.
- Pump is running. fluid is leaking past piston. 3. Change piston seal.
Tool does not operate even though 1. Improper power head & wrench
1. Assemble correctly.
pump is running & all connections are assembly.
2. Replace retractor pin.
properly connected. 2. Retractor pin is sheared.
- Disassemble wrench.
- Clean & inspect
Wrench operation sluggish &/or noisy. Poor lubrication.
- Replace broken parts as needed
- Lubricate all moving surfaces.
Nut partially returns with socket when Torsion on stud is causing nut to
Properly lubricate stud & nut threads.
power head retracts. return with stud.
Nut rotates with socket for power head - Nut too loose & thread friction will
Tighten nut sufficiently before using
extension & returns to starting position not overcome pawl spring.
tool
on retraction - Tool loses “ratchet” capability.
1. Tool is not level or perpendicular 1. Reposition tool &/or reaction arm so
to stud centerline (“out of square” it is level & perpendicular to stud
Nut does not rotate as many degrees
engagement). centerline (perform “floor test”).
as wrench (or socket).
2. Nut corners are rounded off. 2. Replace nut.
3. Socket or hex insert is over-size 3. Use smaller socket or hex insert.
SECTION 8.1
GENERAL HYDRAULIC TROUBLE SHOOTING
FIGURE 8.1-1
GENERAL HYDRAULIC TROUBLE SHOOTING
W-ENG-5525-056 (rev. AD) Page 25 of 40 ENG US
Title: RSL Tool Operation and Maintenance Manual Global
Doc number: W-ENG-5525-056 Revision: AD Date: Aug. 2012
SECTION 9.0
Part Numbers & Drawings
Fig 9.0-1
RSL POWER HEAD
Notes:
1) To order replacement parts specify: Tool Style, Model Number, Serial Number, Description, and Part Number (see part lists).
2) Order all replacement parts from Hydratight (see website).
3) For other tool models refer to original manual or contact Hydratight.
4) Available:
a) Spare Part Kit - Includes seal kit, QD’s (male & female), long & short screws, & retractor pins. e.g. RSLxx-SPK.
b) Seal Kit – Table 9.0-5.
5) 503 moly paste lubricant is part number 100002813 for a 4 lb can
TABLE 9.0-1
RSL POWER HEAD PART LISTS
POWER HEAD MODELS AND PART NUMBERS
ITEM DESCRIPTION QTY
RSL2B RSL4B RSL6A RSL8A RSL14B RSL20 RSL30
1 Housing, Power Head 1 RSL2-1A RSL4-1A RSL6-1A RSL8-1A RSL14-1A RSL20-1 RSL30-1
2 Piston 1 RSL2-2A RSL4-2A RSL6-2 RSL8-2 RSL14-2B RSL20-2 RSL30-2
3 Piston Seal 1 942348 942300 942355 942346 942304 942356 942327
4 Piston Wear Ring 1 942349 942301 942354 942347 942306 942360 942328
5 Front Cap 1 RSL2-3 RSL4-3B RSL6-3 RSL8-3 RSL14-3A RSL20-3 N/A
6 O-Ring (Front Cap) 1 A000282070001 A000282076006 A000282080001 A000282086001 A000282090001 A000282098001 N/A
7 Gland Seal 1 942272 942361 942364 942359 942367 942358 942362
8 Retractor 1 RSL2-5A RSL4-5 RSL6-5 RSL8-5 RSL14-5B RSL20-5 RSL30-5
9 Pin, Retractor 1 A000141183001 A000141183001 921152 921152 RSL14-55 921152 921152
10 Pin, (Inner) 1 N/A N/A A000141185001 A000141185001 A000141165001 A000141185001 A000141185001
11 Block, Bronze 1 RSL2-4A RSL4-4 RSL6-4 RSL8-4 RSL14-4 RSL20-4 RSL30-4
12 Pin, Roll 1 A000141192001 A000141194001 A000141198001 N/A A000141201001 A000141203001 A000141203001
Pin, Roll (or screw) 1 A000141221001
13 N/A A000141194001 RSL6-55 A000151769001 A000141203001 A000141183001
RSL14 - Pin in pin 2 & A000141169001
14 (b) Short Bolt 2 A000151813001 A000151862001 916279 916268 916268 916281 916270
15 (b) Long Bolt 2 RSL2-6 RSL4-6 RSL6-6A RSL8-6 RSL14-6 RSL20-6 RSL30-6
16 Hose, Black - X1-192 (qty 2) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1)
17 Hose, Blue - - X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1)
18 QD, Male 1 936541 936541 936541 936541 936541 936541 936541
19 QD, Female 1 936543 936543 936543 936543 936543 936543 936543
20 Relief Valve 1 X1-21 X1-21 X1-21 X1-21 X1-21 X1-21 X1-21
21 Plug 1 936633 936633 936633 936633 936633 A000371564001 Not Available
22 Sign, Safety 2 RSL-308 RSL-308 RSL-308 RSL-308 RSL-308 RSL-308 RSL-308
Reaction Arm
23 1 RSL2-70A RSL4-70A RSL6-70 RSL8-70A RSL14-70A RSL20-70 RSL30-710
Assembly
24 (a) Overlay, Console 1 X1-18 X1-1 X1-15 X1-14 X1-5 X1-16 X1-6
25 (a) Model Plate 1 N/A N/A RSL6-100A RSL8-100 N/A N/A RSL30-100
Hex Key - for short
27 (a) 1 913007 (1/4) 913009 (5/16) 913012 (3/8) 913023 (1/2) 913021 (5/8) 913021 (5/8) 913022 (3/4)
screw
Hex Key – for long
28 (a) 1 N/A N/A N/A N/A 913020 (1/2) N/A N/A
screw
29 (a) Hex Key – for hex head 1 913001 (3/32) 913001 (3/32) 913003 (5/32) 913003 (5/32) 913005 (3/16) 913005 (3/16) 913005 (3/16)
30 (a) End Cap (not shown) 1 N/A N/A N/A N/A N/A N/A RSL30-3
31 (a) End Cap Seal(s) 1 N/A N/A N/A N/A N/A N/A 942334&942335
32 (a) End Cap Bolts 22 N/A N/A N/A N/A N/A N/A A000151829001
33 (a) Gland Wear Ring 1 N/A N/A N/A N/A N/A N/A 942326
Note: (a) - Not shown. (b) - See Section 6.4-1 for bolt torque specifications. (c) – Use Hydratight HF-101 Oil at Assembly
TABLE 9.0-3
RSL SQUARE DRIVE WRENCH HEAD PART LISTS
SQUARE DRIVE MODELS AND PART NUMBERS
ITEM DESCRIPTION QTY RSL2SA RSL4S RSL6S RSL8S RSL14S RSL20S RSL30S
1 PAWL 1 RSL2S-3 RSL4S-3 RSL6S-3 RSL8S-3 RSL14S-3 RSL20S-3 RSL30S-3
2 SPRING 1 (2) 950291 950302 950250 950250 (2) 950255 950263 950263 (2)
3 HOUSING 1 RSL2S-10A RSL4S-10 RSL6S-10 RSL8S-10 RSL14S-10 RSL20S-10 RSL30S-10
4 ASSEMBLY, PAWL DRIVER 1 RSL2S-20 RSL4S-20 RSL6S-20 RSL8S-20 RSL14S-20 RSL20S-20 RSL30S-20
5 DRIVE, SQUARE 1 TA2S-40 TA4S-40 TA6S-40 TA8S-40 TA14S-40 RSL20S-40 RSL30S-40
6 DRIVER, SQUARE 1 RSL2S-4 RSL4S-4 RSL6S-4 RSL8S-4 RSL14S-4 RSL20S-4 RSL30S-4
7 ASS’Y, RETAINER, SQUARE 1 TA2S-44 TA4S-44 TA6S-44 TA6S-44 TA14S-44 RSL30S-44 RSL30S-44
RSL20-70
(Stainless
Steel)
FIGURE 9.0-4
RSL REACTION ARM PART LISTS
TABLE 9.0-4
TABLE 9.0-5
POWER HEAD SEAL KITS
Item Number 1 2 3 4 5 6 7
End End
Piston Rod Cap Cap
Piston
Seal Kit RSL Model Wear Rod Seal Wear Front Cap Seal Seal Seal
Seal
Ring Ring
(groove) (corner)
RSL2-SKRD RSL2 (rev D) A000282015001 n/a n/a n/a
RSL2 n/a n/a n/a
942348 942349 A000282070001
RSL2-SK RSL2A 942272 n/a n/a n/a
RSL2B n/a n/a n/a
RSL4-SK RSL4* A000282019001 942299 942302 n/a
RSL4-SKA RSL4A 942300 942301 n/a A000282026001 n/a n/a
942361
RSL4-SKB RSL4B n/a A000282076006 n/a n/a
RSL4-SKV RSL4A 942370 942301 942371 n/a A000282026004 n/a n/a
RSL6-SKRC RSL6 (rev C) A000282023001 n/a n/a n/a
RSL6-SK RSL6 942355 942354 n/a A000282080001 n/a n/a
942364
RSL6-SKA RSL6A n/a n/a n/a
RSL8-SKRH RSL8 (rev H)** A000282026001 n/a n/a n/a
942346 942347 A000282086001
RSL8-SK RSL8A 942359 n/a n/a n/a
RSL14-SK RSL14 (N.A.) Not Available (N.A.) (N.A.) n/a (N.A.) n/a
RSL14-SKA RSL14A 942304 942306
342367 n/a A000282090001 n/a n/a
RSL14SKB RSL14B
RSL20-SK RSL20 942356 942360 942358 n/a A000282098001 n/a n/a
RSL30-SKRL RSL30 (rev L) A000282084001 n/a
942327 942328 942326 942335 942334
RSL30-SK RSL30 942362 n/a
* RSL4 Models with End Cap - Hydratight highly recommends using RSL4-IT Installation Tool at assembly. RSL4-IT is sold
separately and not included in RSL4-SK.
** Some older RSL8 Front Caps are reworked and have two grooves (small in front and big in back). Use big groove and square
seal. Do not install both seals.
0.75 10 105000 16226 1.750 97 134 147 160 147 172 210 272
0.875 9 105000 22499 1.750 154 214 235 255 235 275 335 436
1 8 105000 29556 1.750 229 319 349 379 349 409 499 650
1.125 8 105000 38928 1.750 331 464 509 553 509 598 731 953
1.25 8 105000 49588 1.750 459 647 710 773 710 836 1024 1338
1.375 8 105000 61537 1.750 616 873 958 1044 958 1130 1387 1815
1.5 8 105000 74774 1.750 805 1145 1258 1372 1258 1485 1825 2393
1.625 8 105000 89300 1.750 1028 1468 1615 1761 1615 1908 2348 3081
1.75 8 105000 105115 1.750 1289 1846 2032 2218 2032 2404 2961 3890
1.875 8 105000 122218 1.750 1591 2285 2516 2747 2516 2979 3673 4829
2 8 105000 140609 1.750 1936 2787 3071 3354 3071 3638 4489 5908
2.25 8 105000 181258 1.750 2768 4001 4412 4823 4412 5235 6468 8524
2.5 8 105000 227061 1.750 3808 5524 6096 6668 6096 7240 8956 11816
2.75 8 95000 251540 1.583 4597 6687 7383 8080 7383 8777 10866 14350
3 8 95000 302307 1.583 5979 8718 9631 10544 9631 11457 14195 18760
3.25 8 95000 357738 1.583 7613 11123 12293 13463 12293 14633 18142 23992
3.5 8 95000 417832 1.583 9520 13933 15404 16875 15404 18347 22760 30116
3.75 8 95000 482589 1.583 11720 17180 19000 20821 19000 22641 28101 37201
4 8 95000 552010 1.583 14236 20896 23116 25337 23116 27557 34217 45318
4.25 8 75000 494284 1.250 13490 19825 21937 24049 21937 26161 32496 43055
4.5 8 75000 556453 1.250 16023 23573 26090 28607 26090 31124 38674 51258
503 – MOLYBDENUM DISULFIDE BASED (FUNCTIONAL EQUIVALENT C670, MOLY – COTE G PASTE)
504 – MOLYBDENUM LEAD OXIDE AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C100)
505 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT N1000)
506 – NICKEL AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT NICKEL EASE N5000, NEVER – SEEZ NICKEL SPECIAL)
507 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C5A, NEVER SEEZ)
TABLE 10.0-2
0.75 10 105000 11358 1.225 68 94 103 112 103 120 147 191
0.875 9 105000 15749 1.225 108 150 164 178 164 192 235 305
1 8 105000 20689 1.225 160 223 245 266 245 287 350 455
1.125 8 105000 27249 1.225 232 325 356 387 356 418 512 667
1.25 8 105000 34712 1.225 321 453 497 541 497 585 717 937
1.375 8 105000 43076 1.225 431 611 671 731 671 791 971 1270
1.5 8 105000 52342 1.225 563 801 881 960 881 1040 1278 1675
1.625 8 105000 62510 1.225 720 1028 1130 1233 1130 1336 1643 2157
1.75 8 105000 73580 1.225 902 1292 1423 1553 1423 1683 2073 2723
1.875 8 105000 85552 1.225 1113 1599 1761 1923 1761 2085 2571 3380
2 8 105000 98426 1.225 1355 1951 2149 2348 2149 2547 3143 4136
2.25 8 105000 126881 1.225 1937 2801 3089 3376 3089 3664 4528 5967
2.5 8 105000 158943 1.225 2666 3867 4267 4668 4267 5068 6269 8271
2.75 8 95000 176078 1.108 3218 4681 5168 5656 5168 6144 7606 10045
3 8 95000 211615 1.108 4185 6102 6741 7381 6741 8020 9937 13132
3.25 8 95000 250417 1.108 5329 7786 8605 9424 8605 10243 12700 16795
3.5 8 95000 292482 1.108 6664 9753 10783 11813 10783 12843 15932 21081
3.75 8 95000 337812 1.108 8204 12026 13300 14574 13300 15848 19670 26041
4 8 95000 386407 1.108 9965 14627 16181 17736 16181 19290 23952 31722
4.25 8 85000 392132 0.992 10702 15728 17404 19079 17404 20754 25780 34157
4.5 8 85000 441453 0.992 12712 18702 20698 22695 20698 24692 30681 40665
503 – MOLYBDENUM DISULFIDE BASED (FUNCTIONAL EQUIVALENT C670, MOLY – COTE G PASTE)
504 – MOLYBDENUM LEAD OXIDE AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C100)
505 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT N1000)
506 – NICKEL AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT NICKEL EASE N5000, NEVER – SEEZ NICKEL SPECIAL)
507 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C5A, NEVER SEEZ)
SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-1
AMERICAN PETROLEUM INSTITUTE (API) FLANGE SPECIFICATIONS
DIA - STUD DIAMETER (INCHES), NO - NUMBER OF STUDS, AND BCD - BOLT CIRCLE DIAMETER (INCHES)
FLANGE
2,000 PSI 3,000 PSI 5,000 PSI 10,000 PSI 15,000 PSI 20,000 PSI
SIZE
DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD
2-1/16 5/8 8 5 7/8 8 6-1/2 7/8 8 6-1/2 3/4 8 6-1/4 7/8 8 6-7/8 1-1/8 8 9-1/16
2-9/16 3/4 18 5-7/8 1 8 7-1/2 1 8 7-1/2 7/8 8 7-1/4 1 8 7-7/8 1-1/4 8 10-5/16
3-1/16 - - - 1 8 9-1/16 1-1/8 8 9-1/16 1-3/8 8 11-5/16 1-1/8 8 9-1/16 1-3/8 8 11-5/16
3-1/8 3/4 8 6-5/8 7/8 8 7-1/2 1-1/8 8 8 - - - - - - - - -
4-1/16 7/8 8 8-1/2 1-1/8 8 9-1/4 1-1/4 8 10-3/16 1-1/8 8 10-3/16 1-3/8 8 14-1/16 1-3/4 8 14-1/16
5-1/8** 1 8 10-1/2 1-1/4 8 11 1-1/2 8 11-1/2 1-1/8 8 11-13/16 - - - - - -
7-1/16 1 12 11-1/2 1-1/8 12 12-1/2 1-3/8 12 15-7/8 1-1/2 12 16-7/8 1-1/2 16 16-7/8 2 16 21-13/16
9 1-1/8 12 13-3/4 1-3/8 12 15-1/2 1-5/8 12 15-1/2 1-1/2 16 18-3/4 1-7/8 16 21-3/4 - - -
11 1-1/4 16 17 1-3/8 16 18-1/2 1-7/8 12 19 1-3/4 16 22-1/4 2 20 28 - - -
13-5/8 1-1/4 20 19-1/4 1-3/8 20 21 1-5/8 16 23-1/4 1-7/8 20 16-1/2 2-1/4 20 30-3/8 - - -
SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-2
AMERICAN NATIONAL STANDARD (ANSI) FLANGE SPECIFICATIONS
DIA - STUD DIAMETER (INCHES), NO - NUMBER OF STUDS, AND BCD - BOLT CIRCLE DIAMETER (INCHES)
FLANGE
150 300 400 600 900 1,500 2,500
SIZE
DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD
2 5/8 4 4-3/4 5/8 8 5 5/8 8 5 5/8 8 5 7/8 8 8-1/2 7/8 8 6-1/2 1 8 6-3/4
3 5/8 4 6 3/4 8 6-5/8 3/4 8 6-5/8 ¾ 8 6-5/8 7/8 8 7-1/2 1-1/8 8 8 1-1/4 8 9
4 5/8 8 7-1/2 3/4 8 7-7/8 7/8 8 7-7/8 7/8 8 8-1/2 1-1/8 8 9-1/4 1-1/4 8 9-1/2 1-1/2 8 10-3/4
5 3/4 8 8-1/2 3/4 8 9-1/4 7/8 8 9-1/4 1 8 10-1/2 1-1/4 8 11 1-1/2 8 11-1/2 1-3/4 8 12-3/4
6 3/4 8 9-1/2 3/4 12 10-5/8 7/8 12 10-5/8 1 12 11-1/2 1-1/8 12 12-1/2 1-3/8 12 12-1/2 2 8 14-1/2
8 3/4 8 11-3/4 7/8 12 13 1 12 13 1-1/8 12 13-3/4 1-3/8 12 15-1/2 1-5/8 12 15-1/2 2 12 17-1/4
10 7/8 12 14-1/4 1 16 15-1/4 1-1/8 16 15-1/4 1-1/4 16 17 1-3/8 16 18-1/2 1-7/8 12 19 2-1/2 12 21-1/4
12 7/8 12 17 1-1/8 16 17-3/4 1-1/4 16 17-3/4 1-1/4 20 19-1/4 1-3/8 20 21 2 16 22-1/2 2-3/4 12 24-3/8
14 1 12 18-3/4 1-1/8 20 20-1/4 1-1/4 20 20-1/4 1-3/8 20 20-3/4 1-1/2 20 22 2-1/4 16 25 - - -
16 1 16 21-1/4 1-1/4 20 22-1/2 1-3/8 20 22-1/2 1-1/2 20 23-3/4 1-5/8 20 24-1/4 2-1/2 16 27-3/4 - - -
18 1-1/8 16 22-3/4 1-1/4 24 24-3/4 1-3/8 24 24-3/4 1-5/8 20 25-3/4 1-7/8 20 27 2-3/4 16 30-1/2 - - -
20 1-1/8 20 25 1-1/4 24 27 1-1/2 24 27 1-5/8 24 28-1/2 2 20 29-1/2 3 16 32-3/4 - - -
24 1-1/4 20 29-1/2 1-1/2 24 32 1-3/4 24 32 1-7/8 24 33 2-1/2 20 35-1/2 3-1/2 16 39 - - -
SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-3
MANUFACTURER’S STANDARDIZATION SOCIETY OF VALVE AND FITTINGS INDUSTRY, INC.
DIA - STUD DIAMETER (INCHES), NO - NUMBER OF STUDS, AND BCD - BOLT CIRCLE DIAMETER (INCHES)
WARRANTY
Hydratight warrants to original purchaser only that product manufactured by it will be free
from defects in design, materials and workmanship for three years from date on which product is
delivered to original purchaser. EXCEPT AS STATED IN THIS LIMITED WARRANTY,
HYDRATIGHT DOES NOT MAKE AND DISCLAIMS ALL EXPRESS OR IMPLIED
WARRANTIES INCLUDING, BUT NOT LIMITED TO, MERCHANTABILITY OF PRODUCT, ITS
FITNESS FOR A PARTICULAR PURPOSE, ITS DESIGN, CONDITION, OR WORKMANSHIP.
Hydratight’s obligation under this warranty is limited to replacing or restoring (at Hydratight’s
election) any product that is returned intact to Hydratight, or to one of its authorized service stations
with transportation charges prepaid, within warranty period, and that is disclosed, to Hydratight’s
satisfaction, to be defective after its examination.
Original purchaser is responsible for maintaining and replacing field serviceable items such
as fuses, heater coils, filter elements and fluids. Field serviceable items are not warranted by
Hydratight. This warranty shall not apply to any product that has been:
-Repaired or altered outside of Hydratight factory or authorized service stations
-Subject to misuse, abuse, negligence or accident
-Improperly installed or misused. Proper installation and use defined by Hydratight instructions
furnished with product.
HYDRATIGHT WILL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES OF ANY CHARACTER AS A RESULT OF A BREACH OF ITS
LIMITED WARRANTY, INCLUDING WITHOUT LIMITATION: INCONVENIENCE,
TRANSPORTATION COSTS, LOSS OF PROFITS, PROPERTY DAMAGE OR LOST
PRODUCTION, WHETHER SUFFERED BY ORIGINAL PURCHASER OR ANY THIRD PARTY.
Hydratight’s maximum liability under any circumstances will be purchase price of product paid by
original purchaser. Hydratight neither assumes nor authorizes any person to assume for it any
other or greater liability in connection with sale of its products.
Any provision in this limited warranty, including any provision limiting or excluding legal
remedies or warranties or merchantability or fitness for purpose, is not applicable where expressly
prohibited by local law, but only to extent so prohibited.
Any action for breach of this warranty, regardless of legal theory of action, must be brought
within one year after date of breach.
Documentation of date of delivery to original purchaser is required with all requests for
warranty. Contact Customer Service for a “Return Material Authorization” (RMA) number and
shipping instructions. Products returned without an RMA number will not be accepted.