Torque Multipliers, Models 1U-7293, 6V-7820 and 6V-6080

AP300 Asphalt Paver B2Y00001-UP (MACHINE) POWERED BY 3054C Engine(KEBP0336 - 09) - Documentation 16/10/12 19:24
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Product: ASPHALT PAVER

Model: AP-300 ASPHALT PAVER B2Y00356
Configuration: AP300 Asphalt Paver B2Y00001-UP (MACHINE) POWERED BY
3054C Engine
Tool Operating Manual

Torque Multipliers, Models 1U-7293, 6V-7820 and 6V-6080{0599, 0765}
M
Meed
di a N
Nuum
mbbeer - N
NE H S 1149- 01 P u blic
blica ttion Da
Datte -11/ 10/
10/2012
2012 Da
Dat e Upda
Updat ed -11/10/2012
-11/10/2012
i05137209
Torque Multipliers, Models 1U-7293, 6V-7820 and 6V-6080{0599,

0765}
SMCS - 0599; 0765
Caterpillar Products: All
Introduction
European Union Compliant, CE Marked
Important Safety Information
Illustration 1 g02139237
Think Safety
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills, and tools to perform these functions properly.
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Improper operation, lubrication, maintenance, or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have
read and understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
"DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are therefore, not all inclusive. If a tool,
procedure, work method, or operating technique that is not recommended by Caterpillar is used,
the operator must be sure that the procedures are safe. The operator must also be sure that the
product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job.
When replacement parts are required for this product, Caterpillar recommends using Cat
replacement parts or parts with equivalent specifications including, but not limited to physical
dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should
be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from your
service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service
tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools
(DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before operating or performing
maintenance and repair on this service tool.
General Information Section

The General Information Section describes tooling functions and features. This section provides useful
information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator
gains knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
Personal Protection/Important Information
Hazard Avoidance
Crushing Hazard (foot)
Crushing Hazard (hand)
Pinch Point
General Information Section

Description and Design Features

Input and output rotation directions are the same (For example, clockwise input rotation creates clockwise
output rotation). Torque multipliers use planetary gear action to tighten or loosen with a continuous 360°
rotation in either clockwise or counterclockwise direction. On Model 6V-6080 only, an internal bi-
directional anti-backlash device inhibits accidental torque wind-up release.
Note: Reaction force is equal to output force and is in the opposite direction of input/output rotation force.
Reaction bars are held in place using a detent pin or socket head cap screw, depending on the model.
On Models 6V-7820 and 6V-6080, a controlled-shear output square drive protects internal components in
the event maximum output capacity is exceeded. This overload-protection feature causes the drive to
fracture when output exceeds from 3% to 10% of rated output capacity. One replacement controlled-shear
drive is included with both models.
On model 1U-7293 only, the square drive is an integral part of the torque multiplier gear cage assembly.
This model has no overload protection feature.
A selector pawl on model 6V-6080 controls the torque multiplier rotational direction for manually applied
input. The selector pawl is not present on other models.
An approved non-impact power drive may be used with Model 6V-6080 only. Refer to section on
Pneumatic Operations for additional information.
Torque Conversions
A data plate attached to the torque multiplier displays input torque required to obtain listed output torque
values. To calculate a specific input value not listed on the data plate, divide the desired output torque by
the multiplier torque ratio. Refer to the section on Specifications for multiplier torque ratio.
Specifications
Table 1
Model Numbers 1U-7293 6V-7820 6V-6080
750 Ft lb (1020
Output Capacity 1200 Ft lb (1627 2200 Ft lb (2983
Nm)
Nm) Nm)
Input Capacity 250 Ft lb (339 200 Ft lb (271 162 Ft lb (220

Nm) Nm) Nm)
Gear Ratio 4:1 6.33:1 15:1
Torque Ratio 3:1 6:1 13.6:1

Accuracy ±5% of reading from 20% to 100% of full scale rating
Input Drive Female Square Length
Size S1 0.5 In (13 mm) 0.5 In (13 mm) 0.5 In (13 mm)
Output Drive Male Square Length

0.75 In (19 mm) 0.75 In (19 mm) 1.0 In (25.4 mm)
Size S2
Length A
8.53 In (217 mm) 19.56 In (497 19.6 In (498 mm)
mm)
Gearbox
Overall Dimensions 2.81 In (71 mm) 3.94 In (100 mm) 4.06 In (103 mm)
øB
Height C 3.25 In (83 mm) 4.0 In (102 mm) 5.75 In (146 mm)
Net Weight
4 Lb (1.8 kg) 9.1 Lb (4.1 kg) 15.2 Lb (6.9 kg)
Planetary Gear Stages One One Two
Needle Bearings No Yes Yes
Yes, 5° Yes, 5°
Angle-of-Turn Protractor No
increments increments
Torque Conversion Chart No Yes Yes
Shearable Replaceable
No Yes Yes
Output Drive
Selector Pawl,
No No Yes
CW/Neutral/CCW
Anti-Backlash Device No No Yes
Power Drive Compatible No No Yes
Reaction Arm and Square Drive
1. Reaction Bar
2. Socket Head Cap Screw
3. Torque Multiplier
4. Controlled-Shear Output Square Drive (6V-7820 and 6V-6080 Only)
5. Non-Shear Output Square Drive (1U-7293 Only)
6. Detent Pin (1U-7293 and 6V-7820 Only)
Torque Multiplier Dimensions
Input End Details (Model 6V-6080 Only)
1. Rotational direction indicators
2. Neutral positioning set screw
3. Selector pawl
Clockwise (CW)/ Neutral/ Counter-Clockwise (CCW)
4. 1/2 inch female input square drive
Reaction forces increase closer to the multiplier
Note: Forces shown above are general examples only to demonstrate typical differences in force. Refer to
section for multiplier output capacities applicable to models 1U-7293, 6V-7820, and 6V-6080.
Minimize bending moments created by the torque multiplier's reaction
Keep reaction anchor perpendicular to the reaction point.
Note: A torque multiplier with reaction plate is shown in the illustration above. The same instructions and
precautions are applicable to torque multipliers equipped with a reaction bar.
Operation
Instructions
1. When positioning the torque multiplier, be sure the socket attached to the output is positioned so
that the reaction bar is at a right angle to the fastener. Torque reaction creates a rotational force in
the opposite direction from which input force is applied. Refer to Application Information section
for additional torque multiplier reaction information.
2. DO NOT apply more torque than the application can withstand. Breakout torque can be greater than
input torque. Allow a minimum of 50% additional tool capacity for breakout torque. Damaged and
corroded fasteners can require even greater breakout torque capacity.
3. Monitor input torque using a torque wrench. If torque multiplier is used without a torque wrench,
remember that output torque is significantly greater than the input torque.
4. Prolong torque multiplier life. Maintain the shortest possible couple distance between the torque
multiplier output and the fastener being addressed. Maintain the longest distance possible between
the torque multiplier and the reaction point as possible.
5. Model 6V-6080 Only: When using a POWER driven input, lock selector pawl (3) in neutral
position using the neutral positioning set screw (2). Refer to Pneumatic Operation section for
additional information.
6. Protect your warranty. Use only approved output square drives and replacement parts.
Manual Operation (All Models)

1. Read and understand all of the safety precautions included in the Safety Section of this manual.
2. Connect the reaction anchor tube to the torque multiplier (3) using the capscrew (2) or detent pin
(6) .
3. Model 6V-6060 only: Set desired rotation direction by pushing the selector pawl (3) in the direction
indicated by the letters and the directional arrows (1) stamped on the input end of the case.
Example: "CCW" for counter-clockwise rotation. Push pawl to the end of travel in the direction
shown by the "CCW" arrow. For clockwise rotation, push pawl in the opposite "CW" direction.
4. Mount the proper size female square drive socket onto the torque multiplier's output square drive
(4,5). Position socket and the torque multiplier (3) on the fastener to be tightened.
5. Butt the reaction bar securely against a suitable object.
Note: When socket is properly positioned on fastener, reaction bar must be at right angles to the
fastener to which torque is being applied.
6. Mount a 13 mm (1/2 inch) ratchet adapter and torque wrench (user-supplied) into the input of the
torque multiplier.
7. To tighten using a torque wrench: Determine the proper input torque required. (Refer to torque
data plate on the tool or refer to the specification table.) Output torque accuracy requires an accurate
torque wrench in series with the torque multiplier. Apply torque with torque wrench until the
desired input torque is achieved.
8. To remove torque multiplier from fastener: Model 6V-6080 only: Using a torque wrench, apply
enough input torque to release internal anti-backlash device. Maintain torque input and push
selector pawl into opposite position. (Example: Pawl set in "CW" position requires reset to "CCW"
position.) Slowly relax input torque.
Models 1U-7293 and 6V-7820 only: Apply torque to desired rating. Slowly relax input torque and
remove multiplier from application.
9. To loosen using a torque wrench: Replace the torque wrench with a work handle. Models 1U-
7293 and 6V-7820: Apply torque in the opposite direction until fastener is loose.
Model 6V-6080 only: Follow same procedure as for tightening except set the selector pawl in the
opposite position.
Pneumatic Operation (Model 6V-6080 only)

An approved non-impact power drive may be used with Model 6V-6080 only.
Selector pawl must be set in neutral position and the neutral position set screw must be tightened (2) to
lock the selector pawl (3) for power drive unit operation.
When set in the proper position, the selector pawl WILL NOT move in either direction when the neutral
position set screw is tightened.
Make sure that the power drive is set to deliver no more than the maximum allowable input torque. When
equipped with an air pressure regulator, torque output can be controlled.
Models 1U-7293 and 6V-7820 are not designed for use with a power drive. Do not use a power drive with
these models.
Replacing a Square Drive Assembly
Model 1U-7293
Note: Refer to the illustration above during the following steps.
1. Remove retaining ring and circular shims from the input side of the torque multiplier housing.
2. Remove gear cage assembly from the ring gear (torque multiplier housing). The output square drive
is an integral part of the gear cage assembly.
3. Remove input pinion from gear cage assembly with a pulling and twisting motion. Use an arbor
press to remove dowel pins from the planet gears.
4. Replace gear cage assembly with new tool.
5. Reassemble planet gears into cage assembly using arbor press.
6. Lubricate all friction points with high-grade molybdenum disulfide grease.
7. Reassemble input pinion and install assembly into ring gear (torque multiplier housing).
Reassemble shims and retaining ring.
Model 6V-7820
Note: Refer to the illustration above for the following steps.
1. Insert a prying tool under the retaining ring and remove it from the groove in the output gear cage.
Remove the old square drive.
2. Insert the new square drive.
3. Install the new retaining ring into the groove in the output gear cage.
Model 6V-6080
Note: Refer to the illustration above during the following steps.
1. Remove the O-Ring located on the face of the square drive carrier.
2. Remove the square drive retaining pin from the output drive carrier. Pull out the old square drive.
3. Insert retaining pin in output drive carrier. Be certain that the pin engages the hole in the
replacement square drive.
4. Reinstall the O-Ring on the square drive carrier.
Application Information
Torque Multiplier Reaction
There are many different ways of absorbing torque multiplier reaction forces. Although the methods are
as varied as the applications, there are common practices that should be considered.
1. First consider the size and type of torque tool required for the application. Survey space limitations
as well as the maximum torque needed. Allow a minimum of 50% additional capacity in the tool for
breakout torque.
Note: Damaged and corroded fasteners can require even greater breakout torque capacity. Allow a
minimum of 100% over the make-up torque for these conditions. Example: Corroded studs and a
1.36 N·m (1,500 lb ft) make-up torque. Choose a tool with a capacity of at least 4.07 N·m (3,000 lb
ft) for breakout.
2. Select a solid anchor point to minimize deflection. Determine where the reaction forces are going to
take place, for example, against a flange or over an adjacent bolt.
This point must withstand the torque tool reaction forces. Example: A 3,200 Ft lb torque multiplier,
with reaction near the end of the anchor stub produces a reaction force of about 28290.7 N (6360
lb). The reaction force can be reduced to about 10675.7 N (2400 lb) by moving the reaction point
toward the end of the reaction bar. Keep the reaction point tangent to the rotation of the torque
output to prevent increased reaction forces.
3. Keep output torque rotation pure by reducing bending moments. Bending moments decrease torque
efficiency and increase stress on the tool and sockets. Keep the distance between the tool output and
the fastener as short as possible.
4. Increase tool life and increase working environment safety by taking torque reaction as far out on
the reaction anchor as possible.
Angle of Turn Protractor

Models 6V-7820 and 6V-6080 include an angle of turn protractor. This feature allows the operator to
accurately measure a specific number of degrees of rotation of the fastener. The torque/angle of turn
method of tightening fasteners requires a pre-torque value and a specific additional rotation of the fastener
that is engineered into the application. This data will be supplied by the original equipment manufacturer's
engineering department if angle of turn torquing is applicable.
Maintenance Section
Inspection
1. Inspect tooling prior to each use for dents, cracks, bent, or worn parts. If damage is found, destroy
the tool and dispose of as scrap. Replace with new product.
2. Do not use if hardware is damaged or missing.
3. Have the tooling inspected annually by an approved inspector.
Cleaning
Clean the tooling using a non-solvent based cleaner.
Storage
Store the tooling in a clean, dry location to prevent rust or corrosion. The tool should also be stored in the
most stable position.
Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1
International: 1-309-578-7372
Email: dealerservicetool_hotline@cat.com
Copyright 1993 - 2012 Caterpillar Inc. Tue Oct 16 2012 19:22:21 GMT-0500 (ECT)
All Rights Reserved.
Private Network For SIS Licensees.

Torque Multipliers, Models 1U-7293, 6V-7820 and 6V-6080

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AP300 Asphalt Paver B2Y00001-UP (MACHINE) POWERED BY 3054C Engine(KEBP0336 - 09) - Documentation 16/10/12 19:24

Product: ASPHALT PAVER

Tool Operating Manual

Torque Multipliers, Models 1U-7293, 6V-7820 and 6V-6080{0599,

Caterpillar Products: All

Important Safety Information

General Information Section

Personal Protection/Important Information

Crushing Hazard (foot)

Crushing Hazard (hand)

General Information Section

Description and Design Features

Model Numbers 1U-7293 6V-7820 6V-6080

Input Capacity 250 Ft lb (339 200 Ft lb (271 162 Ft lb (220

Torque Ratio 3:1 6:1 13.6:1

Output Drive Male Square Length

Power Drive Compatible No No Yes

Reaction Arm and Square Drive

2. Socket Head Cap Screw

4. Controlled-Shear Output Square Drive (6V-7820 and 6V-6080 Only)

5. Non-Shear Output Square Drive (1U-7293 Only)

6. Detent Pin (1U-7293 and 6V-7820 Only)

Torque Multiplier Dimensions

Input End Details (Model 6V-6080 Only)

1. Rotational direction indicators

2. Neutral positioning set screw

Clockwise (CW)/ Neutral/ Counter-Clockwise (CCW)

4. 1/2 inch female input square drive

Reaction forces increase closer to the multiplier

Minimize bending moments created by the torque multiplier's reaction

Keep reaction anchor perpendicular to the reaction point.

Manual Operation (All Models)

5. Butt the reaction bar securely against a suitable object.

Pneumatic Operation (Model 6V-6080 only)

Replacing a Square Drive Assembly

Note: Refer to the illustration above during the following steps.

4. Replace gear cage assembly with new tool.

5. Reassemble planet gears into cage assembly using arbor press.

6. Lubricate all friction points with high-grade molybdenum disulfide grease.

Note: Refer to the illustration above for the following steps.

2. Insert the new square drive.

Note: Refer to the illustration above during the following steps.

4. Reinstall the O-Ring on the square drive carrier.

Torque Multiplier Reaction

Angle of Turn Protractor

2. Do not use if hardware is damaged or missing.

3. Have the tooling inspected annually by an approved inspector.

Additional Contact Information

USA: 1-800-542-8665, Option 1

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