RSL-OM-1006 hydratight [| RSL OPERATION & MAINTENANCE MANUAL HEX WRENCH SET SALES, PARTS, REPAIR, CALLIBRATION, SERVICE and RENTAL: ‘Western hemisphere: 2440 F. Pasadena Freeway, Pasadena, TX. 77506, el. 713-860-4200, toll free in USA; 1-800-895-3849 Eastern hemisphere: Bentley Road South, Darlaston, West Midlands, WS10 8LQ England, Phone: 0121 50 50 600 Opfional- REPAIR and CALLIBRATION: 2010 Clermont Stet, Antigo, W140, te: 7156278819 fax 715-627-844, ol fee in USA: 100-569-6807 WEB SITE: http:/www.hydratight.com © Hydratight, 2006ABLE OF CONTENTS PAGE SAFETY FIRST ~ SECTION 1 ~ GENERAL BRIEF DESCRIPTION —: PREPARATION FOR OPERATION SECTION 2 - GENERAL OPERATION INSTRUCTIONS GENERAL, TIGHTENING ALTERNATE ~ STUD ELONGATION METHOD LOOSENING STUDINUT SIZE CROSS REFERENCE PRESSURE/TORQUE CONVERSION CHART SECTION 3 ~ RSL POWER HEAD WITH HEX WRENCH HEAD OPERATING INSTRUCTIONS GENERAL 'SEMBLY OF COMPONENTS ~~ GENERAL ASSEMBLY OF COMPONENTS ~ OPERATING RSL TOOL WITH THE SQUARE DRIVE WRENCH HEAD -~ SET-UP AND USE - SECTION $ ~ PREVENTIVE MAINTENANCE, RSL POWER HEAD - RSL HEX AND SQUARE DRIVE WRENCH HEADS SECTION 6 - TROUBLESHOOTING SECTION 7 ~ PARTS RSL POWER HEAD : RSL HEX WRENCH HEAD PARTS LIST ~ RSL SQUARE DRIVE WRENCH HEAD PARTS LIST RSL REACTION ARM ASSEMBLY PARTS LIST SEAL KITS, PARTS LIST AND PLACEMENT GUIDE - RSL TOOL DESCRIPTIONS SECTION 8 - TENSION AND ELONGATION NOTES SAFETY TAG WARRANTY ‘This tool, when used in conjunction with the specified console and hoses, conforms with the requirements for CE Marking. Contact Hyratight fora list of approved components,SAFETY FIRST RSL power tools enable the user to more eaily accomplish bolting tasks with inereasod foes, accuracy, and efficiency. It is due to the powered nature of the tools, with large forees generated from high pressure Auidiair and electricity applied to a variety of applications, that adherence to sict safety issues through the proper design and documented use of RSI. tools. However, the user mist accept the primary responsibilty of safety when using RSL tools by reading, understanding, and complying with all operating instructions prior to and during operation. In a commitment to facilitate user understanding of all operating instructions, HYDRATIGHT offers (upon request) free videotapes and on-site training by a local representative. This manual and additional safety related services are designed to asist in the proper training for use and care of RSL. tools and play a major role in preventing accidents and increasing safety. “The following safty related operating instructions are documented in the manual and on a Safety Tag which should always be attached tothe hydraulic pump when in use Operator must read and understand all operating instructions prior to operations! In addition to this Manual, HYDRATIGHT offers (per request videotapes andor traning onsite by local representative, One-person operation recommended. Only one trained & competent person should contol the operation ofthe tol ‘When two-person operation cannot be avolded a risk assessment must be undertaken that fully address the specific application, communication, co-ordination of the tool operation between the two users, the person HOLDING the ‘wrench should control operations. (Note: The person in control does ot necesarly have the control pendant ins postession, but wil give the conimands to energize the console) Do not use electric pump in explosive or wet environment! Ifelectic pump is used, assure that grounding, power supply, and extension cord meet elettical code, Be aware of electrical hezards Keep hands and fingers clear from pinch points! Pinch points ae present around reaction are and in tight spaces Set reaction properly! Improper reaction set-up andior incorrect socket size will cause a concentration of stress that can make the tool, socket, or nut vulnerable to facture, The common cause of socket breakage is cocking, a condition ‘when socket fis over the bolt at an angle. Read this manual for examples of “bow to” and “how not to” react, with and Without Reaction Arm. ‘High hydraulic pressure hazards, 10,000 psi (690 bar)! Use proper tools, hoses, fittings and protective equipment, © Koop clear of leaking hydraulic Nui. + Never exceed the maximum working pressure. Marking onthe Wrench Head indicates maximam working pressure requirements ‘Wear safety glasses! Eye protection is necessary when working with or near the pressurized hydraulic system. ‘Do not expose hoses to damaging conditions! Hose damage may result from mechanical, thermal, or chemical abuse and may release hydraulic Duid under pressure and eause injury. Disconnect all power supply before performing any maintenance! Maintain equipment in good working condition! Inspect for cracks, wear, and lubricate SWEENEY 503 lubricant. Remove damaged equipment from service. ving parts with Do not modify oF subject any equipment or accessories to impact! Contact HYDRATIGHT for special tool applications or modifications. Unauthorized modifications) may eause injury SGO@O@ODEEEREO o avoid possibility of falling objets in elevated areas, tol must be tied off to application area and reaction arm firmly attached to tol! Reaction arm must be firmly attached with locking Joviso provided as par of arm (Dialoc, ..) and can be further retained by safety cable, Contact Hydratight fr Bulletin 116, which shows how tote reation arm to to! with cable. 3SECTION | GENERAL FIGURE 1-1 RSL POWER HEAD BRIEF DESCRIPTION Ratcheting Slim Line (RSL) Tool is operated with 10000 ps (690 bar? hydrate pets ade wed to apply a specific tension to sds, bots and eap sre by plying te pope torque value fora specie boing mater, size and type of lubacation. The Tool lo wed remove the tension when loeening i netseiry ‘The Tools powsted by a Console (hale pum), The desi tension is achicved by preiely controling Ie yale fd peste produced hy the Conse and contaling the fst force exerted Eetwoen the sus and nus. The ara Mud presute produced by the Conoles is accurate to 1%. The fiction force sontlld by applying a ubricant with a known coefcien of fetion the heads ne ating sures RSL Tool is offered in Seven standard models: GameStats) RSL.2 with maximum torque ouput of 1408 Nt, (1909 Nem) SLA with maximum trgue ouput of S0R0 feb. (176 Nm) RSLS wih maximum torque ouput of 303 RB. (7190 Na) RSLS with ranamum org ouput of 7862 Ib (10660 Nem) RSL1a witha maximum orgie ougpt of 11154 fll (15123 Nem) [RSI20 witha maxeusm logue ouput of 1884 Rb, (25514 Nan) RSL30 witha maimum ogue oot oF 280028 (37966 Na) Caution! Do not modify any equipment or accessories, Contact HYDRATIGHT for special application(s) or modification(s), Unauthorized madification(s) may eause injury and damage, and will invalidate the warranty. PREPARATION FOR OPERATION “Tools are inspected and tsted athe HYDRATIGHT factory pio to Shipment and shuld be ready for immediate wee. However nepeton (of the Tool for damage and verification that all loose porte ate included is recommended, + HYDRATIGHT offers fll torque and tied torque RSL. Wrench Head see mrking onthe housingSECTION 2 GENERAL OPERATING INSTRUCTIONS GENERAL. The sles tobe followed in sletng the corect Tool and Console for the Applicaton and stings the Tool areas follows STEP 1 Determine the torque value 1, The torque value wo be used for applying tension should be the valve Specified by the equipment manofactorer whenever i is avaiable For convenience, chit sf foxgue values for comman sizes of ASTM ‘ALO3 Grades BT and B16 sad an lubricants ere shown in Figures 2- Vand 22. The torgue voles i the charts are based pon the following: Inch size sts ae per ASTM A193, Grade BY or B16, 8 apeicable, with 10 UNC thread form on 38 inch stds, 9 UNC on 78 neh studs, S UNC on | inch sts, and # UN on {1 inch and larger stds Inch size nue ace heavy hex per ASTM A194, Grade 21. Metre size stad Towers ad thread forts are po 11 50; Css 88 and nuts ae por ‘Cass 9. Torque alues listed inthe chars wil produce stud sess ‘qual © 50% for BY and 35% for BUG ofthe minimam yield strength fol the specifi materials, provided the heads and mating sorties are in good condition and have been propery bread wih te specified Ibricant ‘CAUTION: It the stud material, thread form, lubrication, or loading fn {your application # not the same as ured to prepare the chars, do not toe the charts” Contact Iydratight Costomer Serviee forthe bolting ‘analysis of your application, 2, For ler materials, thread forms, Ibreans, or Toading, contact tight Customer Serie to have the rope orgue deteined free ofeharge. The following information mst be provided to determine the proper logic vale for our application: a Sd meter atthe treads dimension ain Figue2-1) 1. Nutsize acres the fat (imension bin Fire 21) ©, Su Grade (BT, BS, BIS ee) ‘4 Librcaton to be used on threads and mating surfess and, if ‘kno, coefieet of ton ofthe arian Desired tension (Gercenage of the yield strength of the stud ‘terial or tensile ses nthe stud) 1. Thrids por ne (mansion en Figre 2-1) or aches pe head (dimension din Fgure 2-1) Extent of heading on thes (length or nly atthe end). Std std or hollows holo, side diameter ofthe ole (Nut ype (regular hex, bemy hex, special tamale diameter, ) 1 the elongation of the stud or rotation ofthe nut methods are used 1 ‘measure the fnson inthe stad, the folloving adonal information must be provide: Desire enon (elongation ofthe stud or rotation ofthe ma). 1 ifthe treading i only at the ends ouside diameter of the sad ‘between the nu fces (mension in Figue 2D, fective bolt length (dimension Fin Figure 2:1). Note: Note the type of gasket material in use, 2 may have an effect {pon the tension required to achieve n good seal. STEP 2 pplication lect the Tool, which best moat the requirements of the Note: When losening, the Tool should be sized for torque values at least | 1.and preferably 2 imes ofthe tightening torque. STEP 3 Sclect the Console, which best meets the requirements ofthe plication, STEP 4, Connect the (othe Console ir oF electrical power source, 2 apical STEP 5. Connect the Twin Hoses to the Console. Bach end of the rose wil ave one male and one ene quick connect iting, The Console wil have like malefemale quick connes ngs. Unscrew te lcking collar ‘on he femile QD. Slide the outed sidering bck and soap the male and Female together eee te slide ing. Sere he locking collar back against the sidering, ‘Slide Ring Locking Collar STEP 6 Connect the Twin Hoses to RSL. Tool, using the Quick CConnset Fitinga, a8 shown in Figure 22, before seing the tol on the ‘pplication, Each end af the hose wl have one male a onefmale quick ones iting The RSL Tool will have ike male/female quick connect fing STEP 7, Set the torque value on the Console according the insructions below for ightningo loosening, as apaiabl STEP &, Set the Tool on the mut and operate in aceordance withthe Instructions in Sesion 3 or Seton 4, Too! Operating Istucon. ba) FIGURE 2-1 STUD AND NUT DIMENSIONFIGURE 2-2 CONNECTING THE TWIN HOSES TO RSL TOOL TIGHTENING |, Mark the coretihtening Soqueeeon the sds in a clackwisediestion with chalk a pe diagram. For more explanation plese 8d ASMESPPC1- 2000 or refer to the Hydeaight int intgity Assurance procedies, 12 Bok Flange 1-9.3-7.11-2.6-1068-12 [Bolt Flange 1-9-6.13-3-11-7-15-210-6-14-412.8416 20 Bot Flange 1-517 9-3-15-719-112-146-18-10416820-12 238 Bok ange 1-13-21-5179.28-315.23-7.191-27-214-22--1810-26 4616:248-2061228, 32 Bol Flange 1-17.925.5.21-13-253-194 22-1426-420-12532-6.24-1628 ‘Note: Coret numbering of tots shoul esl inal odd namhored ols round one sdf the Mange andall even numbered tls aroun heehee Se Determine the Torque Va the sud rbot to be tightened: - 729-18272-18:10-306. ‘st ighening stage shouldbe limited oa maxima of 30% ofthe Final Torque sting Second glening ste shoul! be ited to a maxima of 60% af the final Torque sting Tied ghtening stage shoul be aed out the 100% Torque sting. + Ondhs Fourthnd Finslighienng stage chang im diagnal “Truussting ad tis rod ange unt nus nally soni. ‘tossing sequence andthe uth lage shold be ghtened sing the jason sloekviss Bol tal. sec as shown inthe diagrams abo, For more specific appieaton based procedures plese consult Hydratight Sweeny Joint Integrity Assurance procedures SHYDRATIGHT offers Manssl Conrol Pendant (standard) and Digital Control Pena option, RSLTOOL ‘TWIN LINE HOSES 8 1 ®@1o 7 2 Marked up 8 Bolt Flange @ ® s\e o)3 ®@|® eT 4 84 1%2",&3" Stage 7 2 Criss Cross Sequence 6 3 6 | 4 e.4 4" & Final Stage 7 2 Adjacent Bolt Sequence 6 3 6 | 4 FIGURE 23 FASTENING SEQUENCE FOR CIRCULAR FLANGESpout | smvmum | pour TORQUE FOR SPECIFIED LUBRICANT (FT-188) size | vied | tension [—3r 30 305 300 307 | APISA2 | MACHINE] DRY GN) | smeenorn | “ess” | sme | swine | soeome | seameve | svamere ‘ou | Stee sb) oN. e067 | toss | 100 | rao | e100 STEEL eur_| aso | 200 3a sor Tse Tor Tr aT 7 1a Te TF Tt ae | oso | 24495 161 204 2 256 236 268 3s 3s 1 sooo | 32129 | 249 304 30 30 38 00 9 6 sooo | aig | 300 aa 08 383 508 see 70 383 sooo | S208. | saz is 709 ™ cc ae ws | 337 soon | 68226 | grs 529 os | ons | ose | tos ines | ise sooo | 735 | sm | tom | as | 36 | ss | tase tao | 287 sooo} 9373 | tiae | asak | tos rts | eos |] tase ne | 3016 twsooo | ro9920 | tain | ize | 028 J 2zio | 2028 | 2540 ws | as iwso00 | ramos | ine | 2t00 | sor | 230 | 2807 | 200 joa | ag tws000 | iasise | 2100 | asi | 307 | 3320 | 0x7 | si9 ass | Sera rosea — | teszi0 | 2529 | 348} 360s | oor | 3653 | azar sat | 3009 sooo | tassi | ao | ars | aes | arm | axes | 5067 ons | eso sooo | aoa | 3552 | a4 | si | Seas | Sica | sono rs97 | 0033, tosooo | rx4098 | diss | sis | cos2 | seis | oo | trois tos | 11768 sooo | sesso | some | came | tse | 020 | taza | ssos | tosor | 1a25i sooo | sro0a0 | sas | siso | oss | tos | sss | nin | asia | 18089 soon | oie | sats soas2 | tzz07 | assz? | azz07 | sige | ras | 23907 sooo | aasaor | roast | 13099 | stor | torr | tss07 | roms | 2264 | 30022 soo | aoasat | iagso | teiss | iss7 | 20r07 | tas | 2102 | 27989 | a7001 55000 scasis | 13658 | 19655 ] 2206 | 25006 | 229s | 26760 | 2408s | 45190 soon — | soxoso | asso | isssi | 2isio | 23931 | aisio | sw | 32379 | a2039 asoon__|_sosrst_|_i76se_]22ins_|_ 25951 | 2aers_ | 25001] somo | sases__ | sii NOTE; 503 MOLYBDENUM DISULIFIED BASED (FUNCTIONAL EQUIVALENT 0670, MOLY ~ COTE G PASTE) 08 ~ MOLYBDENUM LEAD OXIDE & GRAPHITE BASED (FUNCTIONAL EQUIVALENT C100) 505 — COPPER & GRAPHITE BASED (FUNCTIONAL EQUIVALENT N1000) S06 NICKEL. & GRAPIITE BASED (FUNCTIONAL EQUIVALENT NICKEL EASE NSO00, NEVER - SEZ NICKEL SPECIAL) 507 COPPER & GRAPHITE BASED (FUNCTIONAL EQUIVALENT CSA, NEVER SEZ) FIGURE 2-4 CHART OF TORQUE VALUES IN IMPERIAL UNITS FOR ASTM A-193 GRADE B7 WITH STUD. STRESS EQUAL TO 50% OF MINIMUM YIELD STRENGTH ALTERNATE - STUD ELONGATION METHOD 3 ‘Te ud elngaton med of metewing tine wed determine he reve ‘eturedf pfu ths anoint of shngsion i sconce wah heures it ‘SShon ens, Tope td Hopton or contact lyri Caso Soviet 1 Sette oat Been charge Then flow es! bog are nd eae ‘8 clnpaion of te deh tas ive ep lyn te og ali ‘Su cane ihc he stu al he prope elongation where. he tae ‘Songer ken he se he rope logan he Cantons Whee nang fastener cae sould be ake to nt wer elongate the {een sed or ange as aly te material ar LOOSENING 1 Adj be Comoe 10.00 ps (0 be rie © mexng he RSL ea me ‘ty mies Forge Cael Kosh cleo + NOTE: HYDRATIONT offesfulogue un linieLisegie vein of RSL Hex 5. (age nh Han Res Ge es) es ry, Rae he matinee ating amped ome wench twang TO ‘spot trped on te Bousng ofthe wrench, the Hex (or square) Wrench Head has 2, Lien apty SWEENEY 50 ena i al he os nthe spin nd leat fork of 3 mes Then staph Tolan he at be ones Imaccdace wire totes a Seston 3, Teoling peat intros ft RSI ante To sen he apace he RS. Too oe sed on he apo inthe oozing {os oo whe exetson wil hve 9 comer cin coon ce ‘Siobat sing wad), Deresr and othe enar Conoa Reon Mote Talo thereto oe oon a pet 2 wt al es ase ‘eyited tum, Tar Caner BOF Bone bus, es he Bs fr pet ‘uta, fart nh putea, be hewn tn popes: fom nel ot ‘Warning: Ifall the tenslon is removed from the first stud to be losened a time rather chan losening al the stads 18 tur fastened studs wll increase and ma re damage to the studs or Mange. the tension in 16 he te sued fo ily orn the ate wae es dan 10% of te tga ga sn tomy my WY me ah 1 te sora eu 40 ly nse the ms wa oer Bas 150% of he tihng tar al rps spe 3 ta 40 nal me fr each m0 ‘evening erin maybe fly eee each egal‘S04 MOLYBDENUM LEAD OXIDE & GRAPHITE BASED (FUNCTIONAL EQUIVALENT C100) 505 — COPPER & GRAPIIITE BASED (FUNCTIONAL EQUIVALENT N000) 506 ~ NICKEL & GRAPHITE BASED (FUNCTIONAL EQUIVALENT NICKEL. EASE NSO00, NEVER-SEEZ NICKEL SPECIAL) 507 COPPER & GRAPHITE BASED (FUNCTIONAL EQUIVALENT CSA, NEVER SEEZ) FIGURE 2-5 OF MINIMUM YIELD STRENGTH srup ‘TORQUE FOR SPECIFIED LUBRICANT (FBS) port | wmmun | norr | cLoNG- z SAI r size | ved | tension | amion [auttive | ante | omare | ante | mene | ATS [MAGINE DEY any | staener ] “cssy” | avers ON ees oth na x10”) sur | eis | 200 Sa a a io ae to | om | tat | ase Be sas 1 | rosoo | 22490 | 1238000 | ny ma | xs | aa | aso io as iim | oso J ao | 122s0m | 353 iss | der | 386 | dos sn ar tua] oso00 | 24 | 22sto0 | 3st ae | so |e | Sn nN By aw] oso00 | asese | 122mm | 4a oo | 30 | oo | m om | iz rua} 0000 | Ssiss | 12asom | is sm | 350 | sa | to |u| ten se | 0so0 | eset | 12asnm | 42 ns | ize | ons | ta | tee | ais ia | toso0 | Sesue | 122sm00 | 988 un fois | tae | tes | doer | ans tam | 0so00 | frre | 22so00 | 220 vss | int | iss | ane | ase | Sans 2" | sosoon | roti | 1225000 | 1370 ans | mae | ans | 2s | ans | an ais | tose | ites? | 1338000 | iam0 asst | anor | 2550 | 20m | ater | ate 21% | tosooo | 31286 | 133500 | 208 sass | Sus | ose | sir | ator | Soe ase | tosoo | tarizs | 1225000 | 287 soz | 9 | as | din | sy] us ain | rosooo | teases | 1225000 | 2908 ao | 40 | a0 | a1 | ae | sae 28 | 95000 | isiooo | tioso | 3si7 sis | soe | sis | 3955 | S505] 1000s 3" | 9sc00o fairies | tosss0 | a5ez cor | su0 | oor | am | sae | i30n six | 9sm0 | dsea87 | tines | Sea ssa | noe | ase | om | naa | tens sin | 9800 | dossaa | iom30 | 31s ions | nis | sons | 24s | istes | tos sue] asooo 3440s | rtows30 | oie | isos | aszar | aos | saat | isaes | isa | 5903 4 | sooo | e360 | rtoKs30 | ose | ase | sono | sees | tooo | iia | asser | tess sia | sso | sovont osmiesr | toss | isoss | asers | tos: | isms | rie | das | 30057 NOTE: S03 MOLYBDENUM DISULPHIDE BASED FUNCTIONAL EQUIVALENT 6570, MOLY-COTE G PASTE) TORQUE VALES IN IMPERIAL UNITS FOR ASTM A193 GRADE B16 WITH STUD STRESS EQUAL TO 35% ‘STUD DIAMETER (INCHES), NUMBER OF STUDS AND BOLT CIRCLE DIAMETER (INCHES) FLANGE| 2,000 PST 3,000 PSI 5,000 PSL 70,000 PST 15,000 PST 20,000 PST Zé [DIA _NO_BCD_[DIA_NO_BCD|DIA_NO_BCD_[DIA_No_ BCD [DIA NO BCD [DIA NO BCD Die [SR 8S [78 8 G12 | 78 8 GID] 34 8 Gl [7 8 6-78 [I-118_8 9-116 zone [3418 S71 8 TD | 1 8 7 | 788 Td | 1 8 Pie d_& 105/16 S116 18 3116 [ C18 738 _8 1-5/6 |-B_& 9-116 [138 1-716 318 [34 8 63 [IR 87-172 [1s 8 SIG [788 81D [88 os [1a 8 TIR_ 8 10316 [388 TAO|aM 814-1716 Sag 1 8 i012 [ia 8 11 [re Ti 8 1-13/16) Tine | 1121-12 [-V8_12 12-12 |e T1212 16-78 [1216 ToT] 216 136 9 [ie 12 13-374 Ps 12_ 15-172 [sis T1216 18-34 [-TI8_16 21-374 Tr [1617 [1-38 1618-172 [1-778 1-34 1622-14 | 2 2028 B58 [4 20-14 [ve 2021-58 1-78 2016-172 F-17420 30-378 16-374 [1-120 23-34 [1-98 2024-104 [1-778 T1824 309/16 134 2 2d_24 36-7116 2034 2203157 DIM [T5R 24 DET | 2 20-29-12 [224 SRTB| 2-12-94 AOI 26-314 [1342037172 | 2 2439-978 ‘*INACTIVE IN 2,00, 3,000 & 5,000 PSI FLANGES FIGURE 2-6 AMERICAN PETROLEUM INSTITUTE (API) FLANGE SPECIFICATIONS 8‘STUD DIAMETER (INCHES), NUMBER OF STUDS AND BOLT CIRCLE DIAMETER (INCHES) “ANGE 150 300 400, 600 900, 7,500 2,500, z&__|DIA_NO_BCD|DIA_NO_BCD|DIA NO BCD|DIA NO BCD|DIA NO_BCD|DIA NO BCD|DIA NO BCD z 38 4 43/4/58 8 5 [58 8 5 [58 8 $5 [78 8 812/78 8 GiI2| 1 8 634 3 oS 4 6 [34 8 65/34 8 658| % 8 GS8|78 8 TZN 8 8 [14 8 9 4 388 T2| 34 8 7-78| 7% _8 778/78 8 812/18 8 9-14 [I-14 8 9-172 [1-172 8 10-34) 5 348 S12;34 8 91a| 78 8 OAL 1 8 101M BT [2 8 TW12| P38 12-94) 6 348 9-1/2) 3/4 12 10-518) 7/8 12 10-S/8| 112 11-1/2|-1/8 12 12-12|t38 12 1212[ 28 14-172) s 348 1-34 7B 1213 | 1 1213 [iW 12 13-3/4| 1-378 12 15-172|0-578 12 15-172 2 12 17-14) 10 TR 12 141al 1 16 15-1ali-18 16 15-174|1-174 16 17 [1-3/8 16 18-1/2|I-7/8 1219 [2-1/2 12 21-174) 2 T1217 [1-8 16 17-31-14 16 17-31-14 20 19-14-37 20 21 | 216 22-1/2|2-3/4 12 24-378) 14 T 12 _18-3/4)1-1/8 20 20-1A[I-174 20 20-1/4|1-3/8 20 20-3/4|1-1/2 2022 (2-1/4 16 25 16 T 16 20-1/4]1-1/4 20 22-172] 1-3/8 20 22-172|1-1/2 20 23-3/4|1-S/8_ 20 24-1/4)2-172 16 27-314] TS___[T-V®_16 22-374] -14 24 24-3413 24 24-314) 1-5/8 20 25-3/4|1-718 2027 [2-3/4 16 30-172 20___[1-W820__25_|i-/4_24 27 [I-12 2437 [1-5/8 24 28-172 2 20 29-172| 316 32-314] 2 11/4 2029-11-12 24 32 [t-34 2432 [I-78 2433 P12 20 351NGI2 16 39 FIGURE 2-7 AMERICAN NATIONAL STANDARD (ANSI) FLANGE SPECIFICATIONS STUD / NUT SIZE CROSS REFERENCE T ‘STUD DIA (INCHES), NUMBER OF STUDS & BOLT CIRCLE DIA (INCHES) PIPE 150 300 4007 600, 900, siz NO__BCD_| DIA__NO_ BCD | DIA__ NO BCD | DIA NO BCD ‘NO__BCD. 12 5 CS 2021 1s 121832020 | IM 2020-14 | 138 2020-378 2022 °F 1625-174 | T-1l20_ 20-05 | 1-920 20-12 | 1-12 2032-378 2024-174 Sm TTT 2027 “0 20s ia 2S 2029-17 2 2027s [i324 29-178 220-1 [13428 24 FS 2a 2035-115 26 24 sae [SRR ID | 828 SI [8 234 2037-12 28. T3488 eT 28 320 40-174 30. 28363428 2830-1 [2 AO S20 a 32 2838-12 1-718 28 2841 [P28 AD] SI 2045-1 3a 3240-12 [1-718 28 Se OT 36 32 aaa [2 32 a OO 38 3245.74 [1 32 32a 98 ASE 3172 2050-378 a0 a 324-1 | 232A] ID 24ST az 3649-12 [13832 30 4B | 21228 SOI | SaaS aa to sia [va 32 30301 | 2192S] 3a ad OTLB a6 453.314 [1-78 28 36 S234 | 21232 Se | OLD a8 456 [2 28 S51 [23432 STR | 2 Rad 30. a sea | 2 32 32 sr 3 280 32 a wo | 32 3s | 3 3262 34 __orsg | a8 28 era [32S 36. a 65) I 28 3264-16 [3G 32665378 38. 4867-378 | 21432 3266-1 | 314326 60. 3269-14 | 214 32 32 e287 FIGURE 2-8 MANUFACTURER'S STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY, INC.NUT/BOLT STUD/BOLT Size Nut/ BOLT stup/ pours we OUTSIDE DIAMETER (A) ouTsibe DIAMETER INCH ae ae Nat W — i {een (oun) TERE a 7 = 30 2088 sien 3 LAH sia a wi EsIGRS 7 3388 8s SOR 7 Fe! a2 24 36 24RB, 22H ae ema 18 7 aa it r 3348 95 212 ARB LS 4 248 sae HY Tiles 0 ar 13/164 46 30RD. 27H sine os aaa no RB aa 234 7 30H 77 Tar 2H Let ‘une 4 EUi6w 18 his sons 55 36RB assist 2 2.3164 1398 7a 30H 2AB tie 4788 a6 7 seu SH sous 2.38 H 112 TH TORE 26H e TS ERE wae jin TRB Tam war Bs ont 23H 70 134 S384 sun Te Re TH TOR 5 178 S301 3:34 150 0H on ‘ 66H 4 KEY: R= REGULAR HEX H=HEAVY HEX B= BOLT OR CAP SCREW FIGURE 2-9 10u STOOL ‘ISU AOA LAVHD NOISUAANOD ANOUOL / TANSSTAd orzaanolSECTION 3 RSL POWER HEAD WITH HEX WRENCH HEAD OPERATING INSTRUCTIONS FIGURE 3-1 RSL HEX WRENCH HEADS GENERAL [RSL Power Hed can be used ith a wide vary of interchangable Hex Wrench Heads (Figure 3-1) for applications with ited access, reduced eight, and lw elesrnce. Hex Wrenca Heads ae valle for all comson hex rt sizes (See Figure 2-9). HYDRATIOHT offers fall Torque aod imited torque versions of RSL Hex. Wrench Heads. Reduced torque (and size) i for limited space aplcations, For lid forgue wrenches, maximum operating posses vary. Refer 10 the rmavimum forge rating stamped on the wrench boating. ‘To avo ‘wrench damage, donot excoodmaimnm torg raing. Hina, toga fang is nt stamped on the housing of the wrench, the Hex Wrench Head has mo toque restrictions, [RSL Powe Hen with Hex Wrench Heads (alt called RSL Tot or Too!) canbe used whe: 2 Overead acesibiliy i Himited and other tooling employing standard lana sockets wil 0 fi 1b. ‘The ghiest weight ols equired, There area limited mumbo of nut sis 4. To eliminate any deflection that may be present when wsing ther teas Quek and cay totso-bolt change i required. Thesmalest nose rai eres for ight bol pater,ASSEMBLY OF COMPONENTS Scoot the Hx Wrench Head to be used and assemble as shown in Figure 3-2. The wrench size (and Masimom torque eating limited torque wrench i sleted) is marked on he sid ofthe wrench, The assembly reires wer to engage he pin into the groove on Paw Driver (ig 32). Ensure that pal diver isi the rated positon bere aterpting sembly. Afer the Hex Wresch Head bas bes property couple 10 the Power Head piston, sccure assembly by Ughtenng th two sort socket head cap serews at lop ad vo Tone ‘socket fad cap seewe st botom of Power Head housing. Is good ractce fo use lubricant (ol) abd tighten those screws to a specie forque to prevent over tightening Use tis gndcine Tor ening, the {ist numer is forte long bolts (RSL3%-6) andthe Second number i forthe short bos: RSL2 stscmblies to 19/23 Rl, RSLA ascmbles 0 35165 fb, RSLS assembles to 6105 fs, KSLA assemblies (0 5/105 fu, RSLS assemblies to 170210R-Ib, RSLL4 assemblies 10 9090 fb, RSL20 sssemblos wo 110/110 feb. and RSL0 assembles to ISILS0 Rob. Contact Haight for ore inermation FIGURE 3-2 RSL POWER HEAD TO HEX WRENCH HEAD ASSEMBLY SET-UP AND USE ‘Adjust the tongue valve on the Console in accordance with the fnsrstons in Section 2, Genes Operating srutons. Place the Hex Wrench Head on the nut w be worked. For mst pplication RSL. fol wil ake reaeon ont oo! housing, a8 shown inPigore 33. Donotoperate she Tooifreaction ie taken on the saline ‘orn of dh oo adage (othe spline wil occur Use Reacion ‘Anmareall HYDRATIGHT for special Reacion Arash ‘application particulars require reution on spline pation oF tool, use of Reaction Arm (supplied wth RSL Too!) i requeed._ Sip the Reaction Arm over the spline portion ofthe Power Head nti i ops agninet o-ring. Resction Arm rast bo aligned lathe same plane (> Tie) ae the wronch ead (fr 3-4). Rotate Dialock in any econ '0 ‘henext ek" (60 depress), to lock Reseton Ar in pac AWarning: Dialock must be in locked position before using Tool! B ‘NOTE: Reasting a sham angle on underside of Reaction Arm as Shown in fi, -nay eause damage Powse Head -spling-andor Reaction Arm_Contact Hystaigh Customer Service or Hysatght Enginsesng for wifi suis owe olin this nner, After ensuring. proper reaction setup, proeeed with tighening or Toosening of msn Secoranes with Seton 2 IMPROPER REACTION ‘DO WOT REACT ON SPLINE FIGURE 33 RSL REACTION METHODS (POWER HEAD WITH HEX, WRENCH HEAD)- without Reaction ArmDO NOT REACT AT AN ANGLE FIGURE 3-4 USING REACTION ARM WITH RSL POWER HEAD AND HEX WRENCH HEAD (Uf Reaction Arm is used, reaction must be in-line with Hex Head as shown) IMPROPER PROPER AVOID ANY ANGULAR ENGAGENENT NO. ANGULAR ADJUSTMENT OO) rccoweo. TW LINE REACTION ONLY 4SECTION 4 RSL POWER HEAD WITH SQUARE DRIVE WRENCH HEAD OPERATING INSTRUCTIONS FIGURE 4-1 ‘SL POWER HEAD WITH SQUARE DRIVE WRENCH HEAD (RSL-SDS) GENERAL, 1. RSL Tool, a¢ shown ia Figure 41, can algo be used with Square Drive ‘Wrench Head, RSL Power Head, whan used witha Square Drive Wrench ‘can wor a varity of ppeaton by employing standard impact sockes, SQUARE MAX TORGUE te ‘mosses RSL DRIVE ‘OUTPUT 2, RSL Power Head wth Square Drive Wrench Head en be sed when: MODEL, (oebes) sebom | ‘Lite or no space limitations exis. RSL, 3a Tae (1909), 1. Ligh weight too iret reduce worker fiigue RSL 7 3080 8176) There area large numberof bls be fastened RSLS. THE 3503. (7150) 8. Masinuen oo! versa is required - mult size applications exist RSL TI a6 (T0680) wit the same ore range, RSE Ta Tiss (5133) RSI Zan, TSA (25547) 3. RSL Power Head coupled with Square Drive Wrench Head is used with RELI ie 2 THRE) impactsockets witha 34° 102 12 square veASSEMBLY OF COMPONENTS The astebly requites the user 10 engage the pn nto the groove on Paw Driver (ig. 32). Ensure thatthe pat driver i nthe rita positon before atempting assembly. Afr the Hex Wrench Heed hasbeen propery coupled to the Power Head piston, sure the aserbly by Tightening the two shor socket eal eap See tp ad two Tong sacket head cap sews a botoms of Power Head hooking It good practie (0 use lubricant (i) and ighten these stews to «spccfe tongue fo prevent ‘over tightening. Use this gudsie for tightening the fest name Yor the long tots (RSI-6) andthe second number i forthe shot Bote [RSL2 essemblis fo 1923 fb, RSLA assemblies to 35/45 fs, RSLS assembles 10 60/05 felts, RSLOA stemblies to 85/108 fib RSLS sssmbles to 170210R-th, RSL assemblies Yo 110/10 Ql, RSL20 Assemblies te 9090 1, and RSL3O assemble to 150150 fs Contact, Hydraight for mre intonation, WINDOWLESS ‘was been EMBED Fam CLARITY FIGURE 4-2 RSL POWER HEAD TO SQUARE DRIVE WRENCH HEAD ASSEMBLY OPERATING RSL POWER HEAD WITH THE SQUARE DRIVE WRENCH HEAD 1, When using the Square Drive Wrench Head with RSL Power Head Is almost always necessary couse tho Reaction Arm (ppd with ISL Power Head). The Reaction Arm used to coumerast the reaction frees cuted as RSL Tool opertes. The Reston AZT, Uwhencter poss, should extend in the destion of the square dive The RSL Reaction Arm is 360 degree adjustable, but the working angle should be within 90 degre (ae oper figure 4-44 and Inprope figure 43), Slip he Reaction Am over the spline potion ofthe Power Head uit it sops agaist oxing. The Renton Arm mst be sige i the Same plate (ia) athe wren hen (fg 3), Rete the Dial (in any direction te the next lick, 60 degrcs 9 Jock Reaeion Arm Inpace, 3. Sette reaction propery! Improper reaction setup andr incorrect socket sie will case a concentration af sees, aking the #00 ange. cic rit naa ecu The como ee ke A trate esha nition when sce ov be a 9 The ling (eoeking) condition may occur when the operat, having ‘sell aca of Reaction Arm engaged, its the Tool over the flange eating an “out of saue” engagement. Anober iing situation is ‘when the Reaction Arm i set aginst sloped object. To cheek if the Tool is going to be set propery, condict & “oor test" where 8 complete RSL Tool assmbly (with socket t be wed om sppieaton} inset on the floor. Push down at the oposite side of Square Drive (Retaining Nu) and chek fora clearance under the Reseioa Aen If leaance is observed, Tool wil eset propel If Wate is m0 space ‘andr Reaction Arm set-up willbe imroper. A Similar est may be performed onthe actual application. IF thee mo space under the Reaction Arm, ROTATE the Aron until space appears. De_ ao _aperate the Tool ifthe reaction i iting the Tool asthe oad d. Injury andor damage tothe Tool may result. Figure $3 nd 4-44 lusts the peer and igh 440 the imprope reaction roth. Push Here “Floor Test” TIGHTENING FIGURE 4-3 PROPER REACTION POINTS FOR RSL REACTION ARM WITH SQUARE DRIVE WRENCH HEADSET-UP AND USE. 6 rv & epee ‘Adjot the torgue value on the Console in accordance withthe ‘nrtreton in Sesion 2, General Operating Instructions. Peston te square deve fo tightening e loosening as shown Figure 45. Tochange diction of square dive frm tightening oseaing (orice) ‘isos style: remove ong around retainer bashing, remove pin, {dit retainer bushing way from ol shown a Figure 4-8. She Sate drive out away fom tol and reposton for denied operation Sexi dive key by reassembling retainer busking, pin and ing. modified sole (ll model): remove Reaining Nut Sige sare tive away fom tol and repostion for desired operation Secure ‘square drive by re-insaling Retaining Nu (Figure 45), Place the dsited size impact speket onthe square drive and sure ropery withthe ong ad pi. Pace te RSL. Power Head withthe Square Drive Wrench Head and Socket on the tore that the Reaction Am is making fn Conact against stonary objet (Ge. an adjcent mut Mange, o& ‘quipment housing) ‘Aer cnsvring proper reaction, Fig. 43 and 4A (aloo read paragraph 3 in OPERATING RSL. POWER HEAD WITH THE SQUARE DRIVE WRENCH HEAD on previous page, proceed with ‘hen or looeening the nus in accordance wih fatroeuons in Section 2 Genel Operating nsruetions, andthe following ditional istrocbons Depress and hold the Manual Contol Pendant* Bution until she Power Head 10d had made compete sake. Return te vod (othe inal positon. The operator shold posh against the re of the Tool (or use other mean of holding) ding this process to insure that reaction arm ism constant const wih the reaction point Continue to work the nt nthe manner wat he Pal does not cage with tne tooth onthe Squire Driver (ool tal). Return te Fo the inal postion om additonal ime and atom to free tr the na Ifthe nut dows no fn, the desi enon hasbeen achieved i he st. The Too! also can be operated withthe Digital Control Pendant, hich ast wn mana Tighten nts accordance with he insrctons in Seton 2, General Operating instachons ‘Move the RSL Too! w the nex! sud. The RSL Power Head, Square Drive Wrench Head scket and Reaction Arm canbe moved a unt fohe nen sud fo Be worked SS, RSLS, HLS, ALES, ALAS LS a LO FIGURE 4-5 POSITIONING THE SQUARE DRIVE PROPER DIRECTIONS B orreaction = {© ©OO FIGURE 4-44, PROPER REACTION POINTS FOR THE RSL REACTION ‘ARM WITH THE SQUARE DRIVE WRENCH HEAD py. = @O@® FIGURE 448 IMPROPER REACTION POINTS/POSITIONS FOR THE RSL REACTION ARM WITH THE SQUARE DRIVE WRENCH HEADSECTION 5 PREVENTIVE MAINTENANCE RSL POWER HEAD. |. Labicate push took (and. siding surface of the Paw Drives) Paridialy with SWEENEY 803 Moly Paste Lubricant. The regency ‘oT ication depends on severity of use and working environment (Chek Retractor, Block and Reva pin for secure before each we 3. Clear dit from the Twiline Hose quck comet couplers before each 4 Ensue that Power Head and Wrench Head are conetly engaged and ‘ighly coupled with socket head cap sees, 5. Cylinder seals "ae designed for Tong hfe, Should seule require replacement because of aks, replace sal ki (3K) RSL2: RSL2-SK; RSLA: RSLASK; RSLE: RSLE-SK; RSL: RSLIE ‘SK: RSL20: RSL20-SK: RSI3O: RSLAO-SK ‘Newer madols have thin eer dating mods version (A, B,.) RSL also have universal sco kit (fr all tmdels) RSL4-SKX, proper sea seletion tobe done on he it, 6. RSL Tool structure, including reneton spline and Reston Ar, should te inepeted regularly to determine If toe are any cracks, chips, oF deformities. “IF any rego are found, immediate Serves. or replacement i rege jsassembly (RSL2, RSL, RS sL14 AND RSL20)— model ‘Cap, see procedure ous versions of RSI-OM for models with Bnd Cap, 1. Ins mating QD's to QD om Power Head wih piston at mid strske. 2. Remove pin joining Reactor with ison, or 10-28 5 socket head cp screw (ob RSLB). Remove push lok end reactor, 3. Using spanner wrench unscrew an remove frat eep. 44 Pullpston sraight out (ase preeue inode), 5S. Replae sels ad wearing as as embly_ (RSI RSL6, RS! 14 AND RSL20) ~ ‘models with Front Cap, sce procedures below of we previous versions of RSI-OM for models with End Cap, 1. Tabet sures with hygraulecil(spectalyfoget contct with the seals). 2. Install fon cap (with seat installed) onto rod. Side cap ox unt it aks conte! withthe piston. 3. Awemble by pressing the above compancnsiato bore wn ron exp ‘comes into emt! with itera teas. A hs point art using Sane? ‘wrench. Tighten fot cap uni fim seated 4, Tighten RSLAA and B models oD IE 5 Reins reactor, push block and the pin, or socket hed cap screw (on RSIS) Disassembly (RSLA with End Cap) ce Figure 5-1, folowing pose 1. Instal mating QD's 1 QD on Power Head wit ol at mi stroke Rernave pin hat hos revactr on piston rd witha punch, Deve piston rearward unl piston res on end cap, ‘With eater oes, dive piston and end exp ou, (se piston 0 keep end «xp square and perpendialar to be). Replace scale and wear rings at need, Assembly (RSL with End Cap) Pres pison to botiom of bore and fill with SWEENEY 509 Hyde Pid high pressure flr hole. 2, Place end cap with new sal in bor wih press, Pash en cap fash wing instalation ol (RSLA-T), Disassembly (RSL14 with End Cap) 1. Insert mating QD's in QD's on Powe Head 2. With piston in mi stoke, remove pin, which holds revscor in place on piston With spinner wrench, remove end cap by ating Counter ochre 3. Pour out hydraulic ol or eyinder Remove piston by pressing on ts ce. (Do na press on spherical rave sure) 4. ‘Replace sal nde wer ring as node Assembly (RSL.14 with End Cup) 1. Insert piston into eytndrall the way to cad of sok, 2. File high pressure inlet ote with ara ‘Screw nen capa Bost ut Disassembly (R130) 1. set mating QD's in QD's on Powe Head 2. With piston in mid stroke, remove pin, which holds rkaetr in ple on piston. 3, Remove 2 ols (5116-2445) that hold end capi place. 4 Remove end cap 5. Pour eu hydraulic oil fom einer. Remove piston by pressing on its end, (Dono press on spherical aus surface) 65, Replice seat andor wearing as needed Assembly (RSIL30 1. tase pst into einer al the way to end of sre, 2. File ighprestore let hole with hydra o, Replace end ap. Tighten (22) S16 alts to 20 lb (dry or with only Tyke i for e980, a " All air shouldbe purged om the tol head before the Power Head is ercd to eves Suggested metho: Connect the Power Head to the congo. Placing the Power Head below the omole and extend the cylinder othe ead of the soe. Remove the power head and comect th hoses together. Turn the eosole on and let rn for 8 minut. Repeat th procedure unt he rod extends and react moby. RSL HEX AND SQUARE DRIVE WRENCH HEADS 1. All moving part should be coated prioaly with SWEENEY 03 Moly Paste Labrcaat The Fequeney of ibrication depends on severity of se snd working environmen. (Check hosing apd otal pats fr craks and wear BSL Hex Wrench “Heads: Loose socket head cap screws joing hex wrench head housings Separts housing halves Retcheing assembly is now expose, Pal end hex driver teh shoud bein corer alignment and prise engagement. Before ase all moving parts shouldbe coated with SWEENEY 305 Moly Paste Lubvicase Hex wrench head components incading Paw, awl Driver, Paw! holding spring, sol hex tench heed housings shuld be inspected regularly to determine if thew ae any cracks, chip, of eformies. "TF any inepularies are found, immediate service or replacement is equiPreventive Maintenance Continued SL Square Drins Wench Heads: Remove Square Drive ftom square drive housing assembly, remove ratcheting assembly aay through bottom of square drive tous. Ratcheting sembly snow exposed. Paw and square vets boul be incorrect ligment and presse engagement. Beer assembly, all moving pats Trou be cowed wilh SWEENEY 308 Moly Pate Labscent Suave Drive Weench Head components including Squae Deve, Square Deve, Pas, Pal Driver, pon! hong spring, and square deve wrench head housing should e inspected rogulaly to dtemne i thet are any cack, chips, or deformities. any replies are found, immediate service or rephcement is required. DISASSEMBLY OF RSL4 POWER HEAD (with End Cap only - older style) ‘SHOWN WITHOUT HOSE LEADS FOR CLARITY PRESS PISTON/ROD PRESS END CAP OUT [AGAINST END CAP, WITH THE PISTON PUSH ON THIS SURFACE (BOTTOM OF DRILLED HOLE) INSTALLATION TOOL (RST) INSTALL PISTON, ‘PRESS END CAP SQUARELY INSTALL SHAP RING. FILL WITH OIL, NTO POsiTION REMOVE EXTRA QD'S SET END CAP IN PLACE \WITH INSTALLATION ‘TOOL (RSL4-MT). (00 NOT PRESS END CCAP ON TOO FAR OR O-RING WILL BECOME (DAMAGED) FIGURE 5-1SECTION 6 TROUBLE SHOOTIN PROBLEM CAUSE SOLUTION. Hydraulic luid leaks from RSL Power Head Power Head Seals are worn. Replace Power Head Seals Power Head Rod does not extend, Torque Gauge shows hydraulic pressure, and the Console is running, Power Head Rod does not retract. Torque {gauge shows hydraulic pressure and the Console is running. 1. Hydraulic line Quick Connect Couplings are improperly connected 2, Hydraulic line Quick Connect Couplings are wor and the Check Valves are not engaging one another. 3, Power Head Seals have flattened and hydraulic fluid is flowing by the Piston. 1. Disconnect hydraulic lines, clean Quick Connect Couplings and securely reconnect the couplings with pliers (on serew-on type couplings). 2. Replace the worn Quick Connect Couplings. 3. Change Seals. Power Head Rod does not fully extend ‘when Too! is not mounted on a stud, 1. Hydraulie system is low on hydraulic uid. 2. Hoses have air in them, 1. Add additional hydraulic Muid in accordance with the applicable Console Operation and Maintenance Manual 2. Connect hose ends together and run pump to force out air. Power Head Rod will not extend at all, the Torque Gauge shows no hydraulic pressure and the Console is running, 1. For System Z1A Consoles, the Four- way Air Valve is sticking due to moisture or dit in the compressed air supply or corrosion of the Four-way Air Valve 2. For System ZF Consoles, the Solenoid Valve is sticking, 1. Clean the Four-way Air Valve 2. Clean the Solenoid Valve, Check line voltage. Tool operates backwards (Advance button retracts piston rod). ‘Quick Connect Couplings are reversed on hhoses, pump, or Power Head. Properly install Quick Conneet Couplings, ‘Tool does not operate even though Console is running and all connections are properly connected. Improper Power Head to Wrench Head assembly has sheared or broken retractor pin. Replace retractor pin if broken, and assemble correctly. ‘Wrench Head operation is sluggish and/or noisy. Insufficient lubrication on push block/paw! driver surfaces, bushing surfaces and for ratcheting mechanism, Disassemble, coat well with SWEENEY 503 Moly Paste Lubricant [Nut partially retums with the Wrench (or socket) when the Power Head Rod retums to initial position Torsion on stud is causing the nut to rtm with the stud. Properly lubricate stud and nut threads. The nut does not rotate as many degrees as the Wrench (or socket) 1. The Tool is not level or perpendicular to the stud centerline (‘out of square” engagement), 2. The comers of the nut being worker are rounded off. 1. Reposition the Tool and/or Reaction Arm so that itis level and perpendicular to the stud centerline (perform “floor test”) 2. Bither replace the nut or use a smaller size Wrench or socket 20TROUBLE SHOOTING & e Console (pump) Female QD Male QD (Ring) SLE |] rerateoo Sate Note: both ends of the same hose {||| Femate ao is coming out of pointed location on extend cycle Mate Female (near) ") = Procedure if 2. Make sure all GD's are tight ‘and/or secured. Y/ (it ‘screw on" type QD's are used, Jaded ring on female QD(s) w/ If leaking continues 3. Replace all male QDs. (low pressure line) If leaking continues [ty 4 Replace Preseure Relist Valve, FIGURE 6-1 TROUBLE SHOOTING DANGER DO NOT ADJUST 21SECTION 7 PARTS LIST ‘When ordering replacement parts, specify the Too! Style, Model Number, Serial Number, Description ofthe replacement parts, and the number listed inthe Parts List. ll replacement parts should be ordered from Hydratight fuctory service (tl, 713-860-4200, 1-800-895-3849). RSL POWER HEAD PARTS 2e ‘eyep y9e}U09 40) aBed jUOAy 99s — wOLOYLEDD 104 AHIR BuOpEsEA JE}UOD 40 pENUEUE (s9po) fouISIL0 0} s2ja4 ‘syed ,s|poUr 49} (C-9"¥°2) 2qume op qn pene da! 9 1, sd sje ‘sane ngs pa Bu one} pe aR) 8.10 WO Jo > Hy ma sued (9p) LM spur aseess |g ot, soa T URLS POTD SECS ze ‘sie dey pua | To06zRIs1000¥. 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L Pie os0HF Siazerix_ | wiaecr ix sriazcr-ix | wraecertx | wadcerIx_ | c6r-X. z SOTSM 07 1SY o-318¥ VoO1SH FV1SH SCISU z L916 182916 392916 612916 | 100298is1000V | 100E [81s 1000¥ z 1 tooestteto09v | 1oocozt+t000v woo6octs1ooov| _ss-978%__| toorett»t000v| _vin. r To0E0z1FL000W | 100<0z1PLO0OW | 100102 Ly 1000 100861 1 1000V | 100¥6I I>LO0oV | 100z6I 1» 1000 1 F-081SY OTIS PISA 91Sa PP ISH YPCISH T 100s8! Ip 1000¥ | 100591 1000V Tooss1 (r1000V] VIN. VIN. c 6 ZsL1z6___| TOOESITTOOOV | TOOET LF TOOOW i socisd | as-+r1se S-#15H S-91SH SIS VSTISH L [Pos puID asech6 i9ecr6 (Ech6 io T9Ezr6 zLtev6 L [ep wo) Towo6078z000¥ | 1od9s0s2000¥ | TOO080z8co0o¥ | ToN9L0zAZoOOW| LoDOLocscoDOy | 9 i dep woag VEPLISY ER1SH e918 ae-F1Sy eTISU s c ura soy wor L¥Lbe6 rsezrs 1orere ec ¥ c ‘orecrs ssecro woecrs € i T0c18H THISH CoISH VeVIS z 1 Pea FOMOd TUSNOH 1-07 1S¥. Vesa, VI-9ISa, Vi-vAsa, L PEO 1OMOd a vsTsu vosa avisa ALO| NOMWdIOsaa wadWAN Lava WalASTI SLUVd GVH HONTYM XIH TSH TL RINDI aio AZIS XAH FHL HLM MOTEE ‘WAWNWAN LIVd IHL NT «XXX» HL SOVIET ALON, © ALSIT SLYVd GVA HON Xost ISHT Suita Peat YoUaAAA 2ALIG| axENbs TSH SL oandey r ‘Algavs NOIS | OOF STSH] _OOESTSH DOESISU] _OOESISU | _00ESISH ‘oor SIsa] OO STSH | T 1 SGOW ALVId | OOL-SOEISA. Vin | oorsrrisu| corssisa | oorsvisa | oorsvisu|oorscisa [or 1 DNREO. VN) TWIN. WN WN VN, WN VIN| 6 L Nid WN WIN YN VIN WIN) VN WN | 8 SVS WaNIvIsY | H-SOeTsy | PrSOETSH PRSPIVA| — PrSOVL | PrSOWL vesbvi | rSevE |e H aRivnds waAnia | r-SOeIsW PSprisa | -Ss1sy | rso7sy rspisu | rScIsy 1 WIATG TUVNOS *A.SSV | OF-SOETSH. OFSrIVI| — OFS8VL | OFSOVL orspvi| _OFSTWL |S (_[WaAria Lava “ATanassy | ocsorisu | oc-sozisy | oc-sprsa | 0z-Se7su | 07-S91SH Ocsrisu| _oc-Scisa | L ONISNOH | OL-S0eISY | OFSOCTSY | —_OFSPIISA | —O1-S8ISw | Or-S9TS¥, OFSPISY, scisu| wr ‘NRIs |] £92056 £92056 sszose| (W)oscos6 | 0szos6 Og0s6. 162056 L Tava | €SorTsa | es0cIsy ESrrISa|ESSISY | ESIISe Esrisa] —_escisu| 1 ‘ALO NoWARDSaa sorisu | S0cIsa SEIISY Sgisy__[S91su SHISH Scisa__| Walt WIGAN LUV SVT Syaeg peay yousrAA aaLig aienbs [syRSL Reaction Arm Assembly Parts List ie i PART NUMBER Descerrrion Jovy siamo staea] note7 [nsisve | SEM Yascao-70 estani0] Aevihe a Figure 7-3 RSL Reaction Arm Assembly Parts List 26Seal Kits Parts List and Seal Placement Guide Geners Seals replacement requires proper procedure to disassemble and assemble Power Head. Please reference to Section 5: Preventive Maintenance. -For ease of identification, each seal is individually packed and clearly marked. Use table and drawing below as a seal placement guide. Parts List -Bvery Seal Kit consists all seals forall respective RSL models. =RSL4-SKV Seal Kit consists seals made of Viton, for special, environment driven applications. Tem Number > 1 2 3 4 é 6 7 ton Seat | Péten Wear reac Ring | Fre nd Cap Seat [End Gap Seal soak | RSLModo! | Piston Soat | Peery Rod Seat | Rod Wear Ring | Front cap Seal | End Cop Seat fend con asus [aooo2s20ts001| 247298 a RSLASK Ravan ia___[Adoa2e2026001 i estas 942300_| o4zso1_| _sez361 ia___[A0od282076001 ie U8 (ev Jaoooza2023001| wa a rste-sk fasue me a a Irs.sa ozs | o4zssa_| _ oxznee ria |000282060001 [na la ovtask PSL Jaaoozszn26001| 242306 rm 942308 a 5-14 eazaoe | otzs0e [342367 ‘va [avon2e2090001| na la Pa 130 fev | [ano0282084007 la eS Fasta0 swaser_|_oazsoe | 910362 942326 wa szs3s | 94204 RSA nnd Cap) a pope asa el i igh ceeded a Laon To-day onan as Seat % Sopa la PdaSi he ton eoonasond aves oer alr hen ane gare ocean’ gooe see et Dt aa Basa, Seal placement guide Seal type dependent installation detail (where applicable) 2RSL TOOL DESCRIPTIONS ‘SQUARE DRIVE WRENCH HEAD (ns, A, A, ALDOR EL POWER HEAD re HL, AON A) CONSOLE (pump) FIGURE 8-2 GENERAL DESCRIPTIONSSECTION 8 TENSION, TORQUE AND ELONGATION ‘TENSION 1, To prevent leakage in bolted connections, itis necessary t0 provide an equal, evenly distributed clamping force around the entire connection. The clamping force must be greater than the anticipated loads applied to the connection However, the tension in the studs due to the sum of the clamping force and the anticipated loads applied 10 the connection must be below the yield point of the stud material, The clamping force is achieved by applying a controlled tensile load to the studs by tightening the nuts. ‘The correct tension is established by equipment ‘manufactures, Codes or Standards depending. upon the application, the tension can be expressed as the tensile stress in the studs, percentage of the yield strength of the stud ‘material, clongation of the studs or degrees of rotation of the fut. ‘The two ways of achieving the desired tension in the studs are applying a controlled amount of torque to the nuts or controlling the elongation of the studs TORQUE 1, To determine the amount of torque which must be applied to the nuts to achieve the desired tension in the studs, the frictional force between the stud and nut threads and mating surfaces must be known and controlled. 2, The required torque value is determined by using of the simplified screw jack formula by Farr which is as follows: F(P ( RF s) 12\20 cosd Whee! forque value in fb, FF = Required tension in the stad in pounds foree. ‘P= Lead oftho toads in inches (Figure 8-1) ‘R= Average mean radius from the axis of he stud out 0 the point ‘where the oad is applied to the thread surface in inches (Figure 8- . 'S Mean Radius of the nut face or shoulder in inches (Figure 8-1) ‘08d = cosine of 1/2 the included thread angle measured on a plane through he axis in degrees (d usually equals 30") J~ Coeicient of friction. 3. The amount of torque to achieve the desired tension in the studs will vary widely depending upon the type of lubricant used due to the variation in coefficients of friction. 4. The coefficient o friction may be controlled through the use ‘ofa lubricant whose coefficient of friction is known 5. To apply the required torque value to the nut the following. ‘must be controlled: 18) The force applied to the Wrench ) The length of the moment arm of the Wrench. 6. The force applied to the Wrench is controlled by regulating ‘and measuring the hydraulic fluid pressure produced by the Console, whose accuracy is traceable to the United States Bureau of Standards, 7. The moment arm length of the Wrench is controlled during the manufacture of the Wrench ELONGATION 1. The amount of elongation of the stud required to achieve the desired tension in the stud is determined by use of the following formula FL AE Were DElongtn ofthe stain inches ‘F= Requited tension in the stud in pounds force. ‘L~ Effective bot length in inches, ‘A= Cross sectional area of the stud at its smallest diameter in square inches. E= Modulus of elasticity. 2. Elongation is determined by measuring the length of the stud before and again after the tensile load is applied to the stud. Ifthe stud was heated to accomplish the elongation, it should be allowed to cool (normally 24 hours) prior to measurement after the tensile load was applied. To accomplish clongation measurements of studs installed in blind holes, @ flat- bottomed hole must be drilled along axis of the studs. 2. The amount of torque required to produce the calculation elongation can be determined by use of the simplified serew FIGURE 8-1 STUD AND NUT DIMENSIONS 29NOTESRSL TOOLS ate designed to operate with either electric oF air hydraulic Console (pump). This manual covers operation ofthe RSL Tools only Operating insiritions forthe purp are covered in the separate manual provided withthe purmp. The tool should not be operated without Safety Tag (shown below) attached tothe pum. hydratight’ hydratight’ SELECTED REACTION FIGURES 2 WARNING __ square DR. WRENCH HEADS a eae ran Mc She ee | wa ee er ome Senter: saa see aaa wesc es Q reernposasarsou @= . oor srake HEX WRENCH HEADS nor EQUPMENT soos LEADING THE WAY. IN BOLTING TECHNOLOGY hydratight “eee O@®@ O@®@ RoLsTAGREVA INSTALL ON THE PUMP INSTALL ON THE PUMP ~— SIDET SIDE 2 31WARRANTY Hydratight warrants to the original purchaser only that the Product manufactured by it will be free from defeets in design, ‘materials and workmanship for three years from the date on which the Product is delivered to the 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. THE MERCHANTABILITY OF THE 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 retumed intact to it, of to one of its authorized service stations with transportation charges prepaid, within ‘the warranty period, and that is disclosed, to Hydratight's satisfaction, to be defective after its examination. The original purchaser is responsible for maintaining and replacing field serviceable items such as fuses, heater coils, filter clements and fluids. ‘The field serviceable items are not warranted by Hydratight. This warranty shall not apply to any Product that has been repaired or altered outside of the Hydratight factory or authorized service stations, or has been subject to ‘misuse or abuse, negligence or accident, or has been installed or used not in accordance with instructions furnished with the product by Hydratight. 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, LOS OF PROFITS, PROPERTY DAMAGE OR LOST PRODUCTION, WHETHER SUFFERED BY THE ORIGINAL, PURCHASER OR ANY THIRD PARTY. Hydratight’s maximum liability under any circumstances will be the purchase price of the product paid by the original purchaser. Hydratight neither assumes nor authorizes and person to assume for it any ‘other or greater liability in connection with the 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 lave, but only to the extent so prohibited, Any action for breach of this warranty, regardless ofthe legal theory of the action, must be brought within one year after the date of breach. Documentation of the date of delivery to the original purchaser is required with all requests for warranty. Contact Customer Service for a “Retum Material Authorization” (RMA) number and shipping instructions. 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