Aztech Systems Impact Driver 16 User Manual

Version 1-2000  
November 2000  
OPERATION AND MAINTENANCE MANUAL  
FOR TX 2, 4, 8, 16, 32  
LOW PROFILE HYDRAULIC TORQUE WRENCHES  
NOTICE  
Series TX-2, TX-4, TX-8, TX-16 and TX-32 Low Profile Hydraulic Torque Wrenches are designed for  
installing and removing large bolts having minimal wrench clearance at offshore platforms, power  
plants, steel erection sites and other locations requiring precise high torque during bolt makeup and  
maximum torque for bolt breakdown.  
Aztec Bolting Services is not responsible for customer modification of tools for applications on which  
Aztec Bolting Services was not consulted.  
WARNING  
IMPORTANT SAFETY INFORMATION ENCLOSED.  
READ THIS MANUAL BEFORE OPERATING TOOL.  
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS  
MANUAL INTO THE HANDS OF THE OPERATOR.  
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY  
.
PLACING TOOL IN SERVICE  
Use the quick connect system to attach the hoses to the  
tool and pump. Make certain the spring-loaded retaining  
rings are fully engaged and the safety rings are tightly  
threaded against the spring-loaded retaining rings to  
prevent the connectors from disengaging under pressure.  
When connecting hoses that have not been preloaded  
with hydraulic oil, make certain the pump reservoir is  
not drained of oil during start-up.  
Always operate, inspect and maintain this tool in  
accordance with American National Standards Safety  
Code for Hydraulic Rams and Jacks (ANSI B30.1)  
This tool will function using an air or electric powered  
hydraulic pump. Adhere to the pump safety  
requirements and follow instructions when connecting  
the pump to the tool.  
Use only equipment rated for the same pressure and  
torque.  
Do not remove any labels. Replace any damaged labels.  
USING THE TOOL  
Use only a hydraulic pump capable of generating  
10,000 psig (681 bar) maximum pressure with this tool.  
Use only twin line hydraulic hose rated for 10,000 psig  
(681 bar) pressure with this tool.  
Do not handle pressurized hoses. Escaping oil under  
pressure can penetrate the skin, causing serious injury. If  
oil is injected under the skin, see a doctor immediately.  
Never pressurize uncoupled couplers. Only use  
hydraulic equipment in a coupled system.  
Always wear eye protection when operating or  
performing maintenance on this tool..  
Do not interchange the male and female swivel inlets  
on the tool or the connections on one end of the hose.  
Reversing the inlets will reverse the power stroke cycle  
and may damage the tool.  
Do not use damaged, frayed or deteriorated hoses and  
fittings. Make certain there are no cracks, splits or  
leaks in the hoses.  
Always wear head and hand protection and protective  
clothing when operating this tool.  
NOTICE  
The use of other than genuine replacement parts may result in safety hazards, decreased tool performance, and  
increased maintenance, and may invalidate all warranties.  
Repairs should be made only by authorized personnel. Refer all communications to Aztec Bolting Services  
For Technical Support and Information Contact:  
Printed in U.S.A.  
Aztec Bolting Services, Inc.  
520 Dallas Street  
League City, TX 77573  
Toll Free: (800) 233-TORK  
Fax: (281) 332-1780  
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PLACING THE TOOL IN SERVICE  
NOT allow the tool to react against the hoses, swivels,  
or inlets.  
ADJUSTMENTS  
3. After having turned the Pump on and presetting the  
pressure for the correct torque, depress the remote  
control button to advance the Piston Assembly. If the  
notch in the piston rod did not engage the Retract Pin in  
the Ratchet Link when the Link was joined to the  
Housing, it will engage the Pin automatically during the  
first advance stroke.  
SETTING THE TORQUE  
After determining the desired torque, use the torque con-  
version chart on the Shroud or the torque conversion  
charts on pages 5 and 6 to determine the pressure that is  
necessary to achieve that torque.  
1. Connect the tool to the power supply and turn the  
pump on.  
4. When the Link is connected to the Housing and the  
wrench is started, the reaction surface of the wrench will  
move against the contact point and the nut will begin to  
turn.  
2. Depress the remote control button causing the  
pressure to be shown on the gauge.  
3. Adjust the pressure by loosening the wing nut that  
locks the pressure adjustment thumbscrew. Rotate the  
thumbscrew clockwise to increase the pressure and  
counterclockwise to decrease the pressure. When  
decreasing pressure, always lower the pressure below the  
desired point and then bring the gauge back up to the  
desired pressure.  
4.When the desired pressure is reached, retighten the  
wing nut and cycle the tool again to confirm that the  
desired pressure setting has been obtained.  
5. When the nut is no longer turning and the Pump  
Gauge reaches the preset pressure, release the remote  
control button. The piston rod will retract when the  
button is released and under normal conditions, an  
audible “click” will be heard as the tool resets itself.  
6. Continue to cycle the tool until it “stalls” and the  
preset psi/torque has been attained.  
7. Once the nut stops rotating, cycle the tool one last  
time to achieve total torque.  
OPERATING THE WRENCH  
LUBRICATION  
Wrench Positions  
Dwg. 2  
Marine Grade Moly Lube  
Lubrication frequency is dependent on factors known  
only to the user. The amount of contaminants in the  
work area is one factor. Tools used in a clean room  
environment will obviously require less service than a  
tool used out-doors and dropped in loose dirt or sand.  
Marine Grade Moly Lube is formulated not to wash out  
of the tool in areas where lubrication is critical.  
Whenever lubrication is required, lubricate as follows:  
1. Separate the Low Profile Driver Assembly from the  
Ratchet Link if they are joined.  
SHROUD  
TIGHTEN  
LOOSEN  
2. After wiping of the old grease, apply a daub of Marine  
Grade Moly Lube to the hooking notch in the Piston  
rod and wipe a film of Moly Lube onto the sides and  
faces of the two Sliders.  
REACT BETWEEN THESE POINTS  
3. Disassemble the Ratchet Link as instructed in the  
Maintenance Section and wash the components in a  
suitable cleaning solution in a well-ventilated area.  
4. Dry the components, then wipe a film of Marine  
Grade Moly Lube onto the wear surface of both Side  
Plate Sleeves and the hubs of the Ratchet.  
The position of the tool relative to the nut determines  
whether the action will tighten or loosen the nut. (Refer  
to Dwg. 2 for application examples). The power stroke  
of the Piston Assembly will always turn the Ratchet Hex  
toward the Shroud.1.Place the Ratchet Hex on the nut.  
Make certain it is the correct size for the nut and that it  
fully engages the nut.  
5. Spread a light film of Marine Grade Moly Lube onto  
the inner faces of both Side Plates covering the area  
where the Drive and Segment Pawl travel. DO NOT  
pack the teeth of the Segment Pawl or Ratchet with  
lube. It can prevent the teeth from engaging properly.  
6. Reassemble the Ratchet Link as instructed in the  
Maintenance Section.  
2. Position the reaction surface against an adjacent nut,  
flange or solid system component. Make certain that  
there is clearance for the hoses, swivels, or inlets. DO  
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TX Series Torque Conversion Chart  
Bar/N.M.  
TX-2  
TX-4  
TX-8  
TX-16  
TX-32  
Hex  
Sizes  
Bar  
3/4" to 1-13/16" 1-7/8" to 2-3/8" All Hex Sizes All Hex Sizes 2-5/8" to 3-15/16" 4" to 4-5/8" 2-7/16" to 4-5/8"4-11/16" to 6-1/2"  
19 to 46MM  
N.m.  
47 to 60MM All Hex Sizes All Hex Sizes 65 to 100MM 105 to 115MM 80 to 115MM  
115 to 155MM  
N.m.  
N.m.  
285  
N.m.  
N.m.  
1,125  
1,357  
1,590  
1,822  
2,055  
2,288  
2,528  
2,768  
3,008  
3,248  
3,489  
3,762  
4,034  
4,307  
4,579  
4,853  
5,063  
5,275  
5,485  
5,696  
5,908  
6,152  
6,396  
6,640  
6,884  
7,128  
7,334  
7,540  
7,747  
7,953  
8,161  
8,386  
8,611  
8,837  
9,062  
9,289  
9,520  
9,754  
9,985  
10,219  
10,452  
10,701  
10,951  
11,200  
11,449  
11,699  
N.m.  
N.m.  
N.m.  
68  
260  
312  
535  
2,115  
2,250  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
#VALUE!  
5,016  
6,019  
82  
342  
644  
2,535  
2,700  
95  
365  
399  
752  
2,955  
3,150  
7,022  
109  
122  
136  
150  
163  
177  
190  
204  
218  
231  
245  
258  
272  
286  
299  
313  
326  
340  
354  
367  
381  
394  
408  
422  
435  
449  
462  
476  
490  
503  
517  
530  
544  
558  
571  
585  
598  
612  
626  
639  
653  
666  
680  
416  
455  
854  
3,382  
3,600  
8,025  
469  
512  
962  
3,802  
4,051  
9,028  
522  
569  
1,071  
1,179  
1,288  
1,389  
1,498  
1,606  
1,715  
1,823  
1,925  
2,033  
2,142  
2,250  
2,359  
2,460  
2,569  
2,677  
2,786  
2,894  
2,996  
3,104  
3,213  
3,321  
3,430  
3,531  
3,640  
3,748  
3,857  
3,965  
4,067  
4,175  
4,284  
4,392  
4,501  
4,602  
4,711  
4,819  
4,928  
5,029  
5,138  
5,246  
5,355  
4,229  
4,501  
10,031  
11,035  
12,038  
13,041  
14,044  
15,047  
16,050  
17,053  
18,057  
19,060  
20,063  
21,066  
22,069  
23,072  
24,075  
25,079  
26,082  
27,085  
28,088  
29,091  
30,094  
31,097  
32,101  
33,104  
34,107  
35,110  
36,113  
37,116  
38,119  
39,123  
40,126  
41,129  
42,132  
43,135  
44,138  
45,141  
46,145  
47,148  
48,151  
49,154  
50,157  
572  
626  
4,650  
4,951  
625  
683  
5,070  
5,401  
678  
740  
5,490  
5,851  
728  
797  
5,917  
6,301  
784  
868  
6,337  
6,751  
832  
923  
6,764  
4,826  
885  
981  
7,185  
7,651  
937  
1,038  
1,097  
1,159  
1,212  
1,270  
1,328  
1,385  
1,450  
1,507  
1,566  
1,624  
1,682  
1,742  
1,799  
1,857  
1,914  
1,972  
2,033  
2,089  
2,146  
2,204  
2,262  
2,325  
2,379  
2,437  
2,494  
2,553  
2,615  
2,669  
2,726  
2,784  
2,843  
2,908  
7,605  
8,101  
990  
8,032  
8,551  
1,045  
1,093  
1,145  
1,197  
1,250  
1,307  
1,353  
1,406  
1,457  
1,510  
1,567  
1,613  
1,666  
1,718  
1,769  
1,829  
1,873  
1,926  
1,979  
2,029  
2,090  
2,134  
2,187  
2,238  
2,291  
2,352  
2,394  
2,447  
2,498  
2,551  
2,614  
8,452  
9,015  
8,879  
9,466  
9,299  
9,916  
9,720  
10,368  
10,818  
11,333  
11,786  
12,240  
12,692  
13,147  
13,692  
14,148  
14,604  
15,061  
15,518  
15,888  
16,342  
16,796  
17,250  
17,630  
18,314  
18,772  
19,231  
19,687  
20,146  
20,361  
20,814  
21,267  
21,718  
22,171  
22,503  
10,147  
10,567  
10,987  
11,414  
11,834  
12,261  
12,682  
13,102  
13,522  
13,949  
14,369  
14,796  
15,217  
15,637  
16,064  
16,484  
16,911  
17,331  
17,752  
18,172  
18,599  
19,019  
19,446  
19,866  
20,287  
20,714  
21,141  
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TX Series Torque Conversion Chart  
P.S.I./FT./lbs  
TX-2  
3/4" to 1-13/16" 1-7/8" to 2-3/8" All Hex Sizes All Hex Sizes 2-5/8" to 3-15/16" 4" to 4-5/8" 2-7/16" to 4-5/8" 4-11/16" to 6-1/2"  
TX-4  
TX-8  
TX-16  
TX-32  
Hex  
Sizes  
19 to 46MM  
ft./lbs.  
192  
47 to 60MM All Hex Sizes All Hex Sizes 65 to 100MM 105 to 115MM 80 to 115MM  
115 to 155MM  
ft./lbs.  
P.S.I.  
ft./lbs.  
210  
ft./lbs.  
395  
ft./lbs.  
830  
ft./lbs.  
1,560  
1,870  
2,180  
2,495  
2,805  
3,120  
3,430  
3,740  
4,050  
4,365  
4,675  
4,990  
5,300  
5,610  
5,925  
6,235  
6,550  
6,860  
7,170  
7,485  
7,795  
8,105  
8,420  
8,730  
9,045  
9,355  
9,665  
9,975  
10,290  
10,600  
10,915  
11,225  
11,535  
11,850  
12,160  
12,475  
12,785  
13,095  
13,405  
13,720  
14,030  
14,345  
14,655  
14,965  
ft./lbs.  
1,660  
1,992  
2,324  
2,656  
2,988  
3,320  
3,652  
3,984  
4,316  
4,648  
4,980  
3,560  
5,644  
5,976  
6,308  
6,650  
6,983  
7,315  
7,648  
7,980  
8,360  
8,694  
9,029  
9,363  
9,698  
10,100  
10,437  
10,773  
11,110  
11,447  
11,720  
12,055  
12,390  
12,725  
13,005  
13,510  
13,848  
14,186  
14,523  
14,861  
15,020  
15,354  
15,688  
16,021  
ft./lbs.  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
1,000  
1,200  
1,400  
1,600  
1,800  
2,000  
2,200  
2,400  
2,600  
2,800  
3,000  
3,200  
3,400  
3,600  
3,800  
4,000  
4,200  
4,400  
4,600  
4,800  
5,000  
5,200  
5,400  
5,600  
3,700  
230  
252  
475  
1,001  
1,173  
1,344  
1,516  
1,688  
1,865  
2,042  
2,219  
2,396  
2,574  
2,775  
2,976  
3,177  
3,378  
3,580  
3,735  
3,891  
4,046  
4,202  
4,358  
4,538  
4,718  
4,898  
5,078  
5,258  
5,410  
5,562  
5,715  
5,867  
6,020  
6,186  
6,352  
6,519  
6,685  
6,852  
7,023  
7,195  
7,366  
7,538  
7,710  
7,894  
8,078  
8,262  
4,440  
269  
294  
555  
5,180  
307  
336  
630  
5,920  
346  
378  
710  
6,660  
385  
420  
790  
7,400  
422  
462  
870  
8,140  
461  
504  
950  
8,880  
500  
546  
1,025  
1,105  
1,185  
1,265  
1,345  
1,420  
1,500  
1,580  
1,660  
1,740  
1,815  
1,895  
1,975  
2,055  
2,135  
2,210  
2,290  
2,370  
2,450  
2,530  
2,605  
2,685  
2,765  
2,845  
2,925  
3,000  
3,080  
3,160  
3,240  
3,320  
3,395  
3,475  
3,555  
3,635  
3,710  
3,790  
9,620  
537  
588  
10,360  
11,100  
11,840  
12,580  
13,320  
14,060  
14,800  
15,540  
16,280  
17,020  
17,760  
18,500  
19,240  
19,980  
20,720  
578  
640  
614  
681  
653  
724  
691  
766  
730  
809  
771  
855  
806  
894  
845  
937  
883  
980  
922  
1,022  
1,070  
1,112  
1,155  
1,198  
1,241  
1,285  
1,327  
1,370  
1,412  
1,455  
1,500  
1,541  
1,583  
1,626  
1,669  
1,715  
1,755  
1,798  
1,840  
1,883  
1,929  
1,969  
2,011  
2,054  
964  
998  
1,037  
1,075  
5,800  
6,000  
6,200  
6,400  
6,600  
6,800  
7,000  
7,200  
7,400  
7,600  
7,800  
8,000  
8,200  
8,400  
8,600  
8,800  
9,000  
9,200  
9,400  
9,600  
1,114  
1,156  
1,190  
1,229  
1,267  
1,305  
1,349  
1,382  
1,421  
1,460  
1,497  
1,542  
1,574  
1,613  
1,651  
1,690  
1,735  
1,766  
1,805  
1,843  
21,460  
22,200  
22,940  
23,680  
24,420  
25,160  
25,900  
26,640  
27,380  
28,120  
28,860  
29,600  
30,340  
31,080  
31,820  
32,560  
33,300  
34,040  
34,780  
35,520  
9,800  
1,882  
1,928  
2,097  
2,145  
3,870  
3,950  
8,446  
8,630  
15,280  
15,595  
16,355  
16,600  
N/A  
N/A  
36,260  
37,000  
10,000  
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TX-2, TX-4, TX-8 SERIES LINK  
TX-16, TX-32 SERIES LINK  
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Part Numbers for Ordering (LINKS)  
TX2  
Part  
TX4  
TX8  
TX16  
TX32  
SIDE PLATE - L  
SIDE PLATE - R  
DRIVE PLATE  
DRIVE PIN  
TX-2-L01 TX-4-L01 TX-8-L01 TX-16-L01 TX-32-L01  
TX-2-L02 TX-4-L02 TX-8-L02 TX-16-L02 TX-32-L02  
TX-2-L03 TX-4-L03 TX-8-L03 TX-16-L03 TX-32-L03  
TX-2-L05 TX-4-L05 TX-8-L05 TX-16-L05 TX-32-L05  
TX-2-L07 TX-4-L07 TX-8-L07 TX-16-L07 TX-32-L07  
TX-2-L09 TX-4-L09 TX-8-L09 TX-16-L09 TX-32-L09  
TX-2-L11 TX-4-L11 TX-8-L11 TX-16-L11 TX-32-L11  
TX-2-L13 TX-4-L13 TX-8-L13 TX-16-L13 TX-32-L13  
1
2
3
4
5
6
7
8
DRIVE PIN SPRING  
RATCHET  
DRIVE SEGMENT  
UPPER SPACER  
MIDDLE SPACER  
N/A  
N/A  
N/A  
TX-16-L14 TX-32-L14  
9
LOWER SPACER  
TX-2-L15 TX-4-L15 TX-8-L15 TX-16-L15 TX-32-L15  
TX-2-L17 TX-4-L17 TX-8-L17 TX-16-L17 TX-32-L17  
TX-2-L19 TX-4-L19 TX-8-L19 TX-16-L19 TX-32-L19  
TX-2-L21 TX-4-L21 TX-8-L21 TX-16-L21 TX-32-L21  
TX-2-L25 TX-4-L25 TX-8-L25 TX-16-L25 TX-32-L25  
TX-2-L27 TX-4-L27 TX-8-L27 TX-16-L27 TX-32-L27  
TX-2-L29 TX-4-L29 TX-8-L29 TX-16-L29 TX-32-L29  
TX-2-L31 TX-4-L31 TX-8-L31 TX-16-L31 TX-32-L31  
TX-2-L33 TX-4-L33 TX-8-L33 TX-16-L33 TX-32-L33  
10  
11  
12  
13  
14  
15  
16  
17  
18  
LOWER SPACER PIN  
SLEEVES - SIDEPLATE  
SHROUD  
SEGMENT SPRING  
SCREWS - UPPER SPACER  
SCREWS - LOWER SPACER  
SHROUD SCREWS  
DRIVE PIN SPRING ROLL PIN  
SPACER ROLL PIN  
N/A  
N/A  
N/A  
TX-16-35 TX-32-L35  
19  
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TX-2, TX-4, TX-8 SERIES CYLINDER  
TX-16, TX-32 SERIES CYLINDER  
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Part Numbers for Ordering (CYLINDERS)  
TX2  
Part  
TX4  
TX8  
TX16  
TX32  
HOUSING  
TX-2-C01  
TX-2-C03  
TX-2-C03-1  
N/A  
TX-4-C01  
TX-4-C03  
N/A  
TX-8-C01  
TX-8-C03  
N/A  
TX-16-C01  
TX-16-C03  
TX-32-C01  
TX-32-C03  
1
PISTON ROD ASSEMBLY  
PISTON ROD  
TX-16-C03-1 TX-32-C03-1  
TX-16-C03-2 TX-32-C03-2  
TX-16-C03-3 TX-32-C03-3  
TX-16-C03-4 TX-32-C03-4  
TX-16-C03-5 TX-32-C03-5  
2
3
PISTON CAP  
N/A  
N/A  
VALVE BALL  
N/A  
N/A  
N/A  
VALVE SPRING  
VALVE HOLLOW LOCK  
PISTON SEAL PLATE  
SEAL RING  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
TX-2-C05  
TX-2-C07  
TX-2-C09  
TX-2-C11  
TX-2-C13  
TX-2-C15  
TX-2-C17  
TX-2-C21  
TX-2-C23  
TX-2-C25  
TX-2-C27  
TX-2-C29  
TX-2-C31  
TX-2-C33  
N/A  
TX-4-C05  
TX-4-C07  
TX-4-C09  
TX-4-C11  
TX-4-C13  
TX-4-C15  
TX-4-C17  
TX-4-C21  
TX-4-C23  
TX-4-C25  
TX-4-C27  
TX-4-C29  
TX-4-C31  
TX-4-C33  
TX-8-C05  
TX-8-C07  
TX-8-X09  
TX-8-C11  
TX-8-C13  
TX-8-C15  
N/A  
N/A  
N/A  
N/A  
4
N/A  
5
SLIDER  
TX-16-C09  
TX-16-C11  
N/A  
TX-32-C09  
TX-32-C11  
N/A  
6
END CAP  
7
RETAINING RING  
LINK PIN  
8
TX-16-C15  
N/A  
TX-32-C15  
N/A  
9
END COVER  
10  
11  
12  
13  
14  
15  
16  
17  
18  
18  
19  
20  
RETAINING SCREWS  
END COVER SCREWS  
BALL PLUNGER  
SLIDER PIN  
TX-8-C21  
N/A  
N/A  
N/A  
N/A  
N/A  
TX-8-C25  
TX-8-C27  
TX-8-C29  
TX-8-C31  
TX-8-C33  
TX-16-C25  
TX-16-C27  
TX-16-C29  
TX-16-C31  
TX-16-C33  
TX-32-C25  
TX-32-C27  
TX-32-C29  
TX-32-C31  
TX-32-C33  
END PLUG SEAL  
ROD SEAL  
PISTON O-RING  
SWIVEL SET  
STX-4M-4M STX-4M-4M STX-4M-4M STX-4M-4M  
SWIVEL SET  
STX-4M-8M  
HC-S100  
TX-2-ST  
N/A  
HC-S100  
TX-4-ST  
N/A  
N/A  
HC-S100  
TX-8-ST  
N/A  
N/A  
HC-S100  
N/A  
N/A  
HC-S100  
N/A  
COUPLER ASSEMBLY  
SEAL INSERTION TOOL  
END PLUG WRENCH  
N/A  
TX-16-EPW TX-32-EPW  
21  
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Maintenance Section  
NOTICE  
WARNING  
The purpose of the Seal Insertion Tool in the  
following step is to prevent the End Plug Seal from  
expanding into the Retaining Ring groove. If the  
Tool is not used, place two thin pieces of flat stock at  
the midpoint of the opening against opposite walls to  
control the Seal expansion.  
Always turn off the power supply, bleed off hydraulic  
fluid from the hose connections on the cylinder  
assembly and disconnect the hoses before attempting  
to repair or perform maintenance on this tool.  
Always wear eye protection when operating or  
performing maintenance on this tool.  
7. Thread one of the Swivel Inlets or a threaded pipe  
with a tee into the End Cap (7). Use the Inlet or tee as  
a handle to pull the End Cap and End Plug Seal (15)  
out of the Housing through the Seal Insertion Tool.  
8. Push the Piston Rod toward the inlet end of the  
Housing and using a hex wrench, unscrew and remove  
the two Retaining Screws (11).  
DISASSEMBLY  
General Instructions  
1. Do not disassemble the tool any further than necessary  
to replace or repair damaged parts.  
2. Use extra care not to score, nick or damage surfaces  
that will contain hydraulic oil under pressure.  
3. Whenever grasping a tool in a vise, always use  
leather–covered or copper–covered vise jaws to  
protect the surface of the part and help prevent  
distortion. This is particularly true of threaded  
members and housings.  
4. Do not remove any part that is a press fit in or on an  
assembly unless the removal of that part is necessary  
for repairs or replacement.  
5. Do not disassemble the hydraulic cylinder assembly  
unless you have a complete set of seals and o–rings for  
replacement.  
9. Insert a hooked tool through each screw hole in the  
Piston Seal Plate (4) and work the Plate upward out of  
the Housing.  
10. Using an o-ring pick, pull the Seal Ring (5) and  
Piston O-ring (17) off of the Piston Rod.  
11. Push the piston end of the Piston Rod forward in the  
Housing until the Slider Pin (14) aligns with the  
cross holes in the Housing.  
12. Using a small drift, tap the Slider Pin out of the  
Sliders (5) and position shaft and remove the two  
Sliders.  
13. Push the piston out of the Housing.  
14. If the Rod Seal (16) needs replacement, use a  
hooked tool to pull it out of the Housing.  
6. Use only British Standard fractional size tools when  
disassembling these tools.  
Disassembly of the TX-16 and TX-32 Cylinder  
Assemblies  
Disassembly of the Tool  
1. Push the Link Pin (9) out of the Housing (1) and Side  
Plates (1 & 2).  
2. Lift the Housing from between the Side Plats and  
separate the two units.  
1. Grasp the Housing (1) in copper-covered or leather-  
covered vise jaws with the inlet end upward and using  
a ¾” wrench, unscrew and remove the two Swivel  
Inlets (18) with their attached Couplers (19).  
2. Remove the housing assembly from the vise jaws and  
over a container to catch the oil, move the Piston Rod  
Assembly (2 & 3) back and forth several times to  
purge the hydraulic oil from the Housing.  
Disassembly of the TX-2, TX-4, and TX-8 Cylinder  
Assemblies  
1. Grasp the Housing (1) in copper-covered or leather-  
covered vise jaws with the inlet end upward and using  
a ¾” wrench, unscrew and remove the two Swivel  
Inlets (18) with their attached Couplers (19).  
2. Remove the Housing Assembly from the vise jaws and  
over a container to catch the oil, move the Piston Rod  
(2) back and forth several times to purge the hydraulic  
oil from the Housing.  
3. Grasp the Housing in copper-covered or leather-  
covered vise jaws with the inlet end upward.  
4. Insert the pins of the End Plug Wrench (21) into the  
holes of the End Cap (7). Using a wrench on the hex  
of the End Plug Wrench, unscrew and remove the End  
Cap with the End Plug Seal (15).  
5. Push the Piston Rod far enough into the Housing to  
expose the hex on the piston head.  
3. Grasp the Housing in copper-covered or leather-  
covered vise jaws with the inlet end upward.  
4. For TX-2 and TX-4 models, use a hex wrench to  
unscrew and remove the End Cover Screw (12).  
Remove the End Cover (14).  
NOTICE  
During removal and after the piston shaft is removed,  
DO NOT grasp the round portion of the shaft with any  
holding device that will damage the surface. Any nicks  
or scratches to the surface will allow hydraulic oil to  
leak from the Cylinder when the tool is reassembled.  
5. Push the End Cap (7) inward approximately ½” and  
remove the two Retaining Rings (8) by working them  
out of the groove in the Cylinder.  
6. Install the Seal Insertion Tool (20) on the inlet end of  
the Housing.  
6. Sprag the flat end of the piston shaft against rotation  
and using a socket on the hex of the piston head,  
- 10 -  
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unscrew and remove the piston head from the shaft  
with the Piston O-ring (17).  
ASSEMBLY  
General Instructions  
1. Use extra care not to score, nick or damage surfaces  
that will contain hydraulic oil under pressure.  
2. Whenever grasping a tool in a vise, always use  
leather-covered or copper-covered vise jaws to protect  
the surface of the part and help prevent distortion. This  
is particularly true if threaded members and housings.  
3. Apply o-ring lubricant to all o-rings before final  
assembly.  
7. Pull the Piston shaft out of the Housing.  
8. If the Sliders (5) must be replaced, position the Slider  
Pin (14) over a clearance opening in a soft block and  
use a small drift to tap the Pin out of the Sliders and  
shaft.  
9. If the Rod Seal (16) needs replacement, use a hooked  
tool to pull it out of the Housing.  
Disassembly of the Ratchet Link  
1. Lay the Ratchet Link flat on a workbench with the  
Left Side Plate (1) downward and using a hex wrench,  
unscrew and remove the two Lower Spacer Screws  
(16).  
2. Using a hex wrench, unscrew and remove the two  
Upper Spacer Screws (15).  
Assembly of the Ratchet Link  
1.If the Side Plate Sleeves (12) were removed, press  
new sleeves, shoulder end trailing, into the Right and  
Left Side Plates (1 & 2) from the inner face of the side  
Plates. Make certain the Sleeves are square with the  
side plate faces and the shoulder of the Sleeves enters  
the recesses in the Side Plates and are pressed flush  
with the faces.  
3. For Series TX-16 and TX-32, use a roll pin punch to  
tap the Spacer Roll Pin (19) out of the Right Side Plate  
(2).  
4. While applying thumb pressure to the edge of the  
Ratchet (6), carefully lift the Side Plate off the  
Assembly.  
2.For Series TX-2, TX-4, and TX-8, position the  
Middle Spacer (9) against the inside face of the Right  
Side Plate Apply a non-permanent thread-locking  
compound to the threads of the two Upper Spacer  
Screws (15) and secure the Spacer with the Screws  
through the Side Plate. For Series TX-16 and TX-32,  
press the Spacer Roll Pin (19) into the Right Side Plate  
with one end of the Pin flush with the external face of  
the Side Plate. Insert the tab of the Upper Spacer (8)  
into the slot in the Middle Spacer (9), and after  
aligning the holes in both pieces, install them on the  
Spacer Roll Pin (19). When they are correctly  
positioned, apply a non-permanent thread-locking  
compound to the threads of the two Upper Spacer  
Screws (15) and secure the Spacers with the Screws  
through the side plate.  
5. Grasp the Ratchet and Drive Plate (3) and, while  
maintaining their relationship, lift them both off the  
Left Side Plate.  
NOTICE  
In the following step, when the Ratchet is removed  
from the Drive Plate, the Drive Segment and Segment  
Spring will be free to fall from the Drive Plate recess.  
Do not allow the Drive Segment to fall on a hard  
surface that might chip the teeth.  
6. Push the Ratchet out of the Drive Plate and Remove  
the Drive Segment (7) and the Segment Spring (14)  
from the Drive Plate Recess.  
3.Insert the two Lower Spacer Pins (11) into the holes in  
the lower edge of the Right Side Plate. Apply a non-  
permanent thread-locking compound to the threads of  
the Lower Spacer Screws (16) and secure the Pins  
with the Screws through the Side Plate.  
4.Place the Lower Spacer (10) over the Pins against the  
Side Plate. Make certain it is correctly oriented so that  
no part of the Spacer extends beyond the edge of the  
Side Plate.  
7. If the Drive Pin (4) or Drive Pin Spring (5) must be  
replaced, use a roll pin punch to push the Drive Pin  
Spring Roll Pin (18) out of the Drive Plate. Once the  
Pin Spring is removed, the Drive Pin (4) will drop  
down to the large opening at the bottom of the slot for  
easy removal.  
8. Lift the Lower Spacer (10) off the Lower Spacer Pins  
(11). If the Pins must be replaced, use a hex wrench to  
remove the two Lower Spacer Screws from the Right  
Side Plate. Pull the Pins out of the holes on the inner  
face of the Right Side Plate.  
5.Insert the Drive Pin (4) into the small cross-hole and  
slot in the Drive Plate (3). Invert the Plate causing the  
ends of the Pin to enter the slot and move the Pin to  
the narrow end.  
9. For Series TX-2, TX-4, and TX-8, unscrew the two  
Spacer Screws and remove the Middle Spacer (9) from  
the Right Side Plate. For Series TX-16 and TX-32,  
use a roll pin punch to remove the Spacer Roll Pin  
(19) from the Right Side Plate. Unscrew the two  
Spacer Screws and remove the Middle Spacer (9) and  
Upper Spacer (8) from the Right Side Plate.  
10. If the Side Plate Sleeves (12) must be replaced,  
press the Sleeves out toward the inner face of the Side  
Plate.  
6.Position the Drive Pin Spring (5) in the drive plate slot  
with the two non-connected ends between the Drive  
Pin and the large hole in the slot. Position the closed  
end of the Spring on the opposite side of the Pin and  
then apply pressure on the Spring to align the hole  
through it with the hole in the Drive Plate for the  
Drive Pin Spring Roll Pin (18). Insert the Spring Roll  
Pin into the Drive Plate, through the Spring and into  
the far wall of the Drive Plate.  
- 11 -  
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9. Wrap the threads of the Swivel Sets (18) with Teflon  
tape and thread the swivel with the male hose Coupler  
(19) into the center of the End Cap. Thread the Swivel  
with the female Coupler into the hole in the Housing  
directly above the End Cap.  
NOTICE  
In the following step, an excessive amount of  
grease will prevent proper tooth engagement  
between the Ratchet and the Drive Segment  
causing the tool to malfunction.  
Assembly of the TX-2, TX-4, and TX-8 Cylinder  
Assemblies  
7.Wipe a thin film of Marine Grade Moly Lube onto the  
inner race of the large opening in the Drive Plate.  
8.Position the Ratchet (6) in the central opening of the  
Drive Plate.  
1. Grasp the link retaining pin lug in copper-covered,  
vise jaws with the Housing (1) horizontal.  
2. If the Rod Seal (16) was removed from the Housing,  
apply a coat of o-ring lubricant to the Seal and install  
it, lip end trailing, in the recess at the bottom of the  
piston bore.  
9.Insert the Drive Segment (7) into the opening adjacent  
to the Ratchet. Make certain the teeth of the Ratchet  
correctly engage the teeth of the Drive Segment.  
Reverse the Ratchet if they do not properly engage.  
10. Slide the Drive Segment sideways to expose the  
spring hole. Install the Segment Spring (14) into the  
hole. While compressing the Spring, slide the Drive  
Segment inward until the Drive Plate captures the  
Segment Spring.  
3. Press the Slider Pin (14) into one of the Sliders (5)  
flush with one side. Install the Pin through the hole in  
the piston shaft and press the remaining Slider onto  
the Pin.  
4. Install the Piston O-ring (17) in the grooves of the  
piston head.  
11. Apply a light coat of Marine Grade Moly Lube to  
both sides of the Drive Plate and Drive Segment.  
Apply some of the Moly Lube to the inner races of  
both Side Plate Sleeves (12).  
12. While keeping the assembly together, insert the hub  
of the Ratchet into the Side Plate Sleeve of the  
assembled Side Plate.  
5. Insert the piston rod, threaded end leading, into the  
small central opening from the non-piston end of the  
Housing. The notch in the trailing end of the shaft  
should be toward the Ball Plunger (13).  
6. Insert the piston, hex end trailing, into the bore of the  
Housing, and use socket to thread and tighten the  
piston onto the piston shaft.  
13. Place the Left Side Plate Sleeve on the hub of the  
Ratchet and align the screw holes for the Spacers.  
14. After applying a non-permanent thread-locking  
compound to the threads and using hex wrenches,  
install the two remaining Lower Spacer Screws.  
7. Install the End Plug Seal (15) in the groove on the hub  
of the End Cap (7).  
8. Using the End Plug Wrench (21), thread the  
assembled End Cap, o-ring end leading, into the piston  
end of the Housing and tighten it.  
9. Wrap the threads of the Swivel Sets (18) with Teflon  
tape and thread the swivel with the male hose Coupler  
(19) into the center of the End Cap. Thread the Swivel  
with the female Coupler into the hole in the Housing  
directly above the End Cap.  
Assembly of the TX-16 and TX-32 Cylinder  
Assemblies  
1. Grasp the link retaining pin lug in copper-covered,  
vise jaws with the Housing (1) horizontal.  
2. If the Rod Seal (16) was removed from the Housing,  
apply a coat of o-ring lubricant to the Seal and install  
it, lip end trailing, in the recess at the bottom of the  
piston bore.  
3. Press the Slider Pin (14) into one of the Sliders (5)  
flush with one side. Install the Pin through the hole in  
the piston shaft and press the remaining Slider onto  
the Pin.  
Assembly of the TX-2, TX-4, and TX-8 Cylinder  
Assemblies  
1. Grasp the link retaining pin lug in copper-covered vise  
jaws with the Housing (1) horizontal.  
2. If the Rod Seal (16) was removed from the Housing,  
apply a coat of o-ring lubricant to the Seal sand install  
it, lip end trailing, in the recess at the bottom of the  
piston bore.  
4. Install the Piston O-ring (17) in the groove of the  
piston head.  
3. Insert the piston rod, notched end leading, into the  
Rod Seal and the small central opening from the  
piston end of the Housing. The notch in the leading  
end of the shaft should be toward the Ball Plunger  
(13).  
5. Insert the piston rod, threaded end leading, into the  
small central opening from the non-piston end of the  
Housing. The notch in the trailing end of the shaft  
should be toward the Ball Plunger (13).  
6. Insert the piston, hex end trailing, into the bore of the  
Housing, and use socket to thread and tighten the  
piston onto the piston shaft.  
4. Push the Piston Rod (2) inward until the hole for the  
Slider Pin (14) aligns with the holes in the walls of the  
Housing.  
7. Install the End Plug Seal (15) in the groove on the hub  
of the End Cap (7).  
5. Position one Slider (6) on each side of the piston shaft  
and insert the Slider Pin through the hole in the  
Housing into both Sliders and the piston shaft. The fit  
between the Pin and Sliders is an interference fit. Use  
a brass hammer and drift to set the Slider Pin below  
8. Using the End Plug Wrench (21), thread the  
assembled End Cap, o-ring end leading, into the piston  
end of the Housing and tighten it.  
- 12 -  
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the outer edge of both Sliders or deep enough to  
prevent the shaft ends from dragging on the Housing  
walls.  
6. Install the Piston O-ring (17) in the internal groove of  
the Seal Ring (5).  
14. Install the Retaining Rings (8) in the housing  
grooves at the inlet end of the Housing. Install the  
Rings with the open ends of both rings at the middle  
of the opening and the beveled side of the Rings  
toward the End Cap.  
7. Install the assembled Seal Ring and Piston O-ring on  
the hub at the large end of the Piston Rod.  
8. Install the Piston Seal Plate (4) in the inlet end of the  
Housing with the side having the countersunk screw  
holes trailing.  
15. If an air hose is available, inject some air into the  
threaded opening of the End Cap to seat the Retaining  
Rings. If air is not available, temporarily thread one of  
the Swivel Sets (18) into the threaded opening and  
pull the End Cap back against the Retaining Rings to  
seat them.  
NOTICE  
16. For TX-2 and TX-4 models position the End  
Cover (10) against the Housing and after applying a  
non-permanent thread-locking compound to the  
threads, install the End Cover Screw (12).  
17. Wrap the threads of the Swivel Sets (18) with  
Teflon tape and thread the swivel with the male hose  
Coupler (19) into the threaded hole in the End Cap.  
18. Apply some Marine Grade Moly Lube to the notch  
in the Piston Rod and the face of the Sliders.  
In the following step, DO NOT use thread-locking  
compound on the screw threads.  
9. Using a hex wrench and an alternating tightening  
procedure, install the Retaining Screws (11). Tighten  
each Screw a little at a time to obtain even  
compression and expansion of the Piston O-ring and  
Seal Ring.  
10. Place the Seal Insertion Tool (20) on the inlet end of  
the Housing.  
Assembly of the Tool  
11. Install the End Plug Seal (15) in the groove of the  
End Cap (7)  
1. With the Cylinder Assembly in one hand and the  
Ratchet Link in the other, hook the notch on the shaft  
of the Piston Rod (2) onto the Drive Pin (4) and bring  
the two assemblies together.  
2. Insert the Link Pin (9) into the hole in the Side Plate (1  
or 2) until the Ball Plunger (13) snaps into the annular  
groove around the center of the Link Pin.  
12. Insert the assembled End Cap into the Housing  
through the Tool with the O-ring end leading and the  
threaded inlet hole downward. Push the Cap inward  
beyond the Retaining Ring groove and approximately  
½” into the Cylinder.  
13. Remove the Seal Insertion Tool from the Housing.  
- 13 -  
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Troubleshooting Guide  
Probable Cause  
Trouble  
Solution  
Couplers are not securely attached to  
the tool or pump  
Check the Coupler connections and make  
certain that they are connected.  
Piston will not advance or  
retract  
Coupler is defective  
Replace any defective Coupler.  
Defective remote control switch  
Dirt in the direction-control valve of  
the pump unit  
Replace the switch and/or control pendent  
Disassemble the pump and clean the  
direction-control valve.  
Make certain the advance on the pump is  
connected to the advance on the tool and  
retract on the pump is connected to the  
retract on the tool.  
Hose connections reversed  
Piston will not retract  
Retract hose not connected  
Connect the retract hose securely  
Retract pin and/or Spring broken  
Replace the broken pin and/or spring  
Piston Seal and/or End Plug Seal  
leaking  
Replace any defective O-rings  
Cylinder will not build up  
pressure  
Retaining Screws sheared  
Coupler is defective  
Replace any broken screws.  
Replace any defective Coupler  
Grease or dirt build up in the teeth of  
the Ratchet and Segment Pawl  
Worn or broken teeth on Ratchet an/or  
Segment Pawl  
Disassemble the Ratchet and clean the  
grease or dirt out of the teeth  
Ratchet will not turn  
Replace any worn or damaged parts  
Depress the advance button to release the  
tool; shut the pump off in the advance  
position and reverse the hose connection  
Inspect, adjust or replace the relief valve  
Make certain the air supply and hose size  
Tool tightens immediately  
when turned on  
Hose connections are reversed  
Defective relief valve  
Air supply too low or air hose too small comply with the pump manual  
recommendations.  
Make certain the amperage, voltage and  
Pump will not build up  
pressure  
Electric power source is too low  
any extension cord size comply with the  
pump manual requirements  
Defective Gauge  
Low oil level  
Replace the Gauge  
Check and fill the pump reservoir  
Inspect, clean and/or replace the pump  
filter  
Clogged filter  
Pressure reading erratic  
Defective Gauge  
Replace the Gauge  
Nut Returns with retract  
stroke  
Ball Plungers are not engaging the  
Drive Sleeves  
Thread the Ball Plungers to the correct  
depth in the Housing.  
NOTICE  
SAVE THESE INSTRUCTIONS. DO NOT DESTROY.  
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