Product Information

• General Information
  • Safety Signal Words
  • Warranty
  • Website
  • ServAid
  • Safety Data Sheets MSDS/SDS
  • Safety Warning
  • Country of Origin
  • Dimensional Drawings
• Overview
  • Low Profile Wrench Overview
  • Technical Data
  • Technical Product Data
• ATEX Certification Information
  • ATEX
  • ATEX Code Definition

General Information

WARNING

Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

• Read all Safety Information delivered together with the different parts of the system.

• Read all Product Instructions for installation, operation and maintenance of the different parts of the system.

• Read all locally legislated safety regulations regarding the system and parts thereof.

• Save all Safety Information and instructions for future reference.

Safety Signal Words

Warranty

• Product warranty will expire 12+1 months after dispatch from Atlas Copco's Distribution Center.

• Normal wear and tear on parts is not included within the warranty.

  • Normal wear and tear is that which requires a part change or other adjustment/overhaul during standard tools maintenance typical for that period (expressed in time, operation hours or otherwise).

• The product warranty relies on the correct use, maintenance, and repair of the tool and its component parts.

• Damage to parts that occurs as a result of inadequate maintenance or performed by parties other than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the warranty.

• To avoid damage or destruction of tool parts, service the tool according to the recommended maintenance schedules and follow the correct instructions.

• Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover contracts. For further information contact your local Service representative.

Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on the Atlas Copco website.

Please visit: www.atlascopco.com.

ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

• Regulatory and Safety Information

• Technical Data

• Installation, Operation and Service Instructions

• Spare Parts Lists

• Accessories

• Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

For further Technical Information, please contact your local Atlas Copco representative.

Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

Safety Warning

Country of Origin

For the Country of Origin, please refer to the information on the product label.

Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

Overview

• Low Profile Wrench Overview
• Technical Data
• Technical Product Data

Low Profile Wrench Overview

The Torcflex low profile wrench (TFX) is a professional hydraulic power tool that is designed to exert torque on industrial fasteners to make sure of correct tightening or loosening of an industrial bolted connection. The tool uses a double acting hydraulic cylinder to transfer linear force into rotation torque through a ratchet mechanism. The torque is controlled by adjusting the pressure applied to the hydraulic cylinder.

The tool includes the following main components:

Technical Data

Dimensions

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

ATEX Certification Information

• ATEX
• ATEX Code Definition

ATEX

Only tools and equipment correctly certified and marked with ATEX symbol should be utilized in potential explosive zones.

Operator must read and understand all operating instructions prior to use!

This (additional) information and guidance must be used in conjunction with the Standard Product and Safety Instructions supplied with all Torcflex hydraulic torque wrenches.

ATEX Zone Operation: Additional care and attention should be applied when working within potentially explosive environments. Special consideration is required with respect to the tightening application and use of the Torcflex range of tools, the operator must perform a risk assessment prior to the use of any Torcflex hydraulic torque wrench within a potentially explosive (ATEX zoned) environment.

It is the operators’ responsibility to maintain the tool to ensure its safe operation within ATEX rated zones. Failure to comply with the maintenance recommendations will increase the likelihood of mechanical failure and therefore the chance of mechanical spark generation.

If the wrench shows any sign of malfunction, remove it from the ATEX zone before investigating the cause. DO NOT attempt to repair the wrench in the ATEX zone.

If the wrench is dropped, remove it from the ATEX zone before looking for damage. Do a pressure test and functional test before using it again.

Torcflex Wrench Inspection

Inspect the general condition of the Torcflex wrench before using the tool in an ATEX zone. Particular attention should be given to the drive components, i.e., the square or hexagon drive, ratchet, and drive pawls. Any parts that are in poor condition or that have had significant use must be replaced. During re-assembly, ensure that the parts are correctly lubricated in accordance with maintenance instructions.

System and Operational Considerations

• Only use Torcflex torque wrenches in ATEX zones when connected with/to other ATEX declared or certified components, e.g., hoses and hydraulic pump.

• Confirm electrical continuity through the torque wrench system. To prevent any static build up, suitably earth / electrically ground the system / pump.

• Additional care should be taken when selecting reaction points and in the placement and support of the hydraulic torque wrench.

• Ensure accessories and sockets used are in good operational order and suitable for use within potentially explosive atmospheres.

ATEX Code Definition

The ATEX code is:
	II 2 G Ex h IIC T4 Gb II 2 D Ex h IIIC T135°C Db -20°C ≤ Ta ≤ 40°C

Installation

• Installation Requirements
  • General Installation Requirements
• Installation Instructions
  • Installing the TL Ratchet Link
  • Installing the RL Ratchet Link
  • Installing the Support Handle
  • Releasing the Pressure
  • Connecting the System - Co-axial Coupling
  • Connecting the Hose to the Pump
  • Connecting the Hose to the Wrench
  • Disconnecting the Hose from the Pump
  • Disconnecting the Hose from the Wrench
  • Connecting the System - Screw-to-Connect Coupling

Installation Requirements

• General Installation Requirements

General Installation Requirements

To operate Torcflex wrenches, connect the wrench to a hydraulic power pack with a hydraulic hose. For maximum efficiency and accuracy, use Atlas Copco torque wrench pumps and hoses. If Atlas Copco pumps and hoses are not used, make sure of the following before connecting Torcflex wrenches:

• System requirements:

  • All system components must have a dynamic pressure rating of 700 bar (10,000 psi).

• Pump requirements:

  • Maximum Advance Pressure: 700 bar (10,000 psi).

  • Maximum Retract Pressure: 120 bar (1,740 psi).

  • Remote-operated directional control valve for operating the double acting cylinder; the pressure must be released when switching between Advance and Retract.

  • For safety, the remote must be configured to automatically retract the tool if the button is released.

  • Adjustable pressure relief valve.

  • Calibrated pressure gauge (Class 1 Accuracy).

  • For screw-to-connect coupling systems, make sure that the Advance coupling is male and the Retract coupling is female. For more information, refer to section Connecting the System - Screw-to-Connect Coupling.

  • Torcflex wrenches fitted with screw-to-connect couplings use CEJN 232 couplings with ¼ NPT threads. Before using alternative brand couplings in the system, verify the compatibility. For more information, refer to section Connecting the System - Screw-to-Connect Coupling.

• Hydraulic hose requirements:

  • Advance line − female to female coupling.

  • Retract line − male to male nipple.

Before connecting the system, do the following:

• On electric pumps, make sure that the power supply is appropriate for the pump and minimize the length of extension cords.

• On pneumatic pumps, make sure that the air supply is appropriate for the pump and minimize the length of air lines.

• Look for any damage on the power and pendant cables before connecting the cables to the power supply.

• Look for any damage on the hydraulic hoses and couplings before connecting the hoses to the system.

• Inspect the oil level and fill if necessary.

• Make sure that the pressure gauge is calibrated.

• Make sure that the impact sockets are the correct size for the application.

• Make sure that the impact sockets are free from damage.

• Select a wrench based on the target torque for the application.

  To prolong the lifespan of the wrench, do not operate the tool above 80% capacity for long periods. As with any machine, operating it continuously at maximum capacity will reduce its lifespan. It will also need maintenance and replacement of worn parts more often.

• For applications where the back nut can rotate, make sure that a suitable backup wrench is available.

Installation Instructions

• Installing the TL Ratchet Link
• Installing the RL Ratchet Link
• Installing the Support Handle
• Releasing the Pressure
• Connecting the System - Co-axial Coupling
• Connecting the Hose to the Pump
• Connecting the Hose to the Wrench
• Disconnecting the Hose from the Pump
• Disconnecting the Hose from the Wrench
• Connecting the System - Screw-to-Connect Coupling

Installing the TL Ratchet Link

Make sure that the piston rod end and drive plates are lubricated properly before installation.

Inserting the Ratchet Link

Installing the RL Ratchet Link

Make sure that the piston rod end and drive plates are lubricated properly before installation.

Inserting the Ratchet Link

Installing the Support Handle

Make sure that the handle has the correct bolt size before you install the handle onto the wrench. Two support handle screw sizes are available; select the correct bolt size from the list.

• TF01 / TFX02 = M6

• TF03/05/08/10 / TFX04/08 = M8

The wrench supports the installation of the support handle at three different positions.

Side positions, left or right:

Front position:

Powerhead side position, left or right:

Preparing the Handle for Installation

Installing the Handle on the Wrench

Adjusting the Handle Position

The bolt does not need to be loosened to adjust the handle position.

You can turn the support handle to 12 positions in 30-degree increments:

Releasing the Pressure

Torcflex wrenches can be supplied with either co-axial couplings or screw-to-connect couplings. The co-axial coupling system connects both the advance line and retract line with a single connection. The screw-to-connect coupling system requires the advance and retract lines to be connected individually. Before connecting, make sure that the couplings are clean and free of damage.

Before you try to connect or disconnect hydraulic couplings, make sure that there is no residual pressure in the pump.

Electric Pumps

Pneumatic Pumps

All couplings should be easily connected and disconnected by hand. If not, look for damage or residual pressure in the system.

Connecting the System - Co-axial Coupling

The co-axial system connects both the advance and retract lines of the hydraulic circuit using a single coupling.

Connecting the Hose to the Pump

Connecting the Hose to the Wrench

Disconnecting the Hose from the Pump

The co-axial coupling has a safety feature to prevent accidental disconnection during use. Learn how to disconnect the hose before using the equipment.

If the connections are not pushed together and held, the knurled collar cannot move, therefore the couplings cannot be disconnected. This is a safety feature to prevent accidental disconnection.

Disconnecting the Hose from the Wrench

The co-axial coupling has a safety feature to prevent accidental disconnection during use. Learn how to disconnect the hose before using the equipment.

If the connections are not pushed together and held, the knurled collar cannot move, therefore the couplings cannot be disconnected. This is a safety feature to prevent accidental disconnection.

Connecting the System - Screw-to-Connect Coupling

Atlas Copco pumps and hoses have the couplings pre-configured to operate Torcflex wrenches as shown below.

If you use non-Atlas Copco equipment to operate Torcflex wrenches, make sure that the couplings are configured as shown.

1

Wrench

2

Pump

Make sure that all couplings are connected properly with no gaps between the collars and the fittings. Never use wrenches or other tools to tighten or loosen couplers.

Make sure that the connectors are fully engaged and screwed tightly together.

Never use two twin hydraulic hoses between the pump and the tool. To avoid tool malfunction, do not reverse the connectors. Do not try to tighten or loosen any couplings under pressure.

Operation

• Ergonomic Guidelines
• Operating Instructions
  • Operation Safety
  • Working Pressure
  • Setting the Target Torque
  • Operating the Low Profile Wrench
  • Checking the Drive Direction
  • Tightening
  • Loosening

Ergonomic Guidelines

Consider your workstation as you read through this list of general ergonomic guidelines to identify areas for improvement in posture, component placement, or work environment.

• Take frequent breaks and change work positions frequently.

• Adapt the workstation area to your needs and the work task.

  • Adjust for a convenient reach range by determining where parts and tools need to be located to avoid static load.

  • Use workstation equipment such as tables and chairs appropriate for the work task.

• Avoid work positions above shoulder level or with static holding during assembly operations.

  • When working above shoulder level, reduce the load on the static muscles by lowering the weight of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce the load on the static muscles by holding the tool close to the body.

  • Take frequent breaks.

  • Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.

• Adjust for a convenient field of vision that requires minimal eye and head movements.

• Use appropriate lighting for the work task.

• Select the appropriate tool for the work task.

• In noisy environments, use ear protection equipment.

• Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibration.

Operating Instructions

• Operation Safety
• Working Pressure
• Setting the Target Torque
• Operating the Low Profile Wrench
• Checking the Drive Direction
• Tightening
• Loosening

Operation Safety

WARNING

High-Pressure Fluids Hazard

Never grab, touch, or in any way come in contact with a hydraulic pressure leak. When the hydraulic circuit is pressurized, the hydraulic fluid can escape at high speed. Escaping fluid under pressure can penetrate the skin causing serious injury. If an accident occurs, contact the nearest health service immediately! Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

• Always relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

• Always wear safety approved eye wear when checking for leaks. Do not use your hands to check for leaks in the hydraulic circuit.

• Always keep away from leaking elements during the tightening process.

• Always wear impact-resistant eye and face protection when involved with or near the operation, repair or maintenance of the unit.

• Be sure all others in the area are wearing impact-resistant eye and face protection.

• Even small projectiles can injure eyes and cause blindness.

WARNING

Risk of Severe Injury

Always protect the face when working with high-pressure equipment. High-pressure equipment could cause severe bodily injury.

• Always wear goggles and/or face shield.

• Monitor the pressurized equipment and pay attention to the pressure gauge, because the pressure can increase quite rapidly in case of low volume circuits.

WARNING

Crushing Hazard

Keep hands away from the reaction areas during operation! The tool could entrap fingers or other body parts if not kept away. Moving parts can crush and cut.

Working Pressure

All system components must have a dynamic pressure rating of 700 bar (10,000 psi). If other than Atlas Copco pumps and hoses are used, make sure that the equipment is suitable for use with Atlas Copco wrenches.

Pump Working Pressure:

• Maximum Advance Pressure: 700 bar (10,000 psi)

• Maximum Retract Pressure: 120 bar (1,740 psi)

Setting the Target Torque

Once the wrench is set up and connected to a pump, you must set the target torque output. To set the torque output, you must adjust the pressure output value at the pump.

A

Knurled lock nut

B

T-handle

1

Advance button

0

Stop button

Operating the Low Profile Wrench

Prerequisites

• Wear personal protective equipment: Correct and appropriate safety equipment must be worn.

• Always perform a task-based risk assessment before using the tool.

• Frequently inspect the tool, power pack, hoses, connectors, electric cables, and accessories for visible damage. Always follow instructions for tool and pump maintenance.

• Select the appropriate size low clearance ratchet link and insert it into the tool. Tool operation, bolt tightening and loosening, is determined by the position of the tool relative to the nut/bolt.

• Connect the hoses: Make sure that all hose connections are secure and correctly made. Make sure that the hoses are free from defects.

Start up

1. Cycle the tool: Place the tool on a flat surface, turn the pump on. Press and hold the Advance [1] button on the pump remote control pendant until the tool clicks. Release the button, wait for the tool to click. Repeat.

2. Set the pressure: Press and hold the Advance [1] button and slowly turn the pressure regulator clockwise to reach the correct pressure.

3. Place the tool on the nut to be tightened or loosened.

   The driving stroke of the power head will always turn the hex ratchet (and therefore the nut) towards the shroud at the front of the tool, that is, turning away from the reaction point. The low clearance ratchet links are supplied complete with a long reaction block. This reaction block is designed to react against an adjacent nut.

The ratchet link has been designed so that the reaction block reacts against an adjacent nut or other suitable secure reaction point. If such a reaction point is not available, standard reaction accessories are available, or if necessary, special reaction arms can be supplied.

WARNING

Crushing Hazard

Keep hands away from the reaction areas during operation! The tool could entrap fingers or other body parts if not kept away. Moving parts can crush and cut.

Make sure that the nut corresponds with the tool size.

Always make sure to use a solid reaction point during operation.

Never kink or bend hoses excessively:

Never strike wrench to assist breakout:

Checking the Drive Direction

Before you use the wrench, make sure that the direction of rotation is correct. The direction is indicated by the arrow on top of the tool.

The reaction arm will rotate in the opposite direction to the drive until it contacts a suitable reaction point.

1	Loosen: counterclockwise Tighten: clockwise
2	Reaction arm
3	Direction arrow

If the direction of rotation needs to be reversed, turn the wrench over and install it on the application.

Tightening

Loosening

If the fasteners are heavily corroded or have been subject to high temperature in service, the break loose torque can be more than double that of the tightening torque. Use a larger tool for loosening than for tightening. To make loosening easier, remove all surface rust with a wire brush and apply releasing oil to the nut, bolt, and bearing surface. Allow sufficient time for the oil to soak in and penetrate before trying to loosen the fastener.

When loosening fasteners, there can be a sudden release of energy when the fastener breaks free. This can cause an unexpected shock force on the tool. To protect the drive components, do not exceed 90% of maximum pressure during loosening. If 90% does not loosen the fastener, use a larger tool if possible.

Never strike a wrench or socket with a hammer to assist loosening operations.

Service

• Maintenance Instructions
  • Service and Maintenance Recommendations
  • Preventive Maintenance
  • Overhaul Instructions
• Lubrication Instructions
  • Lubricant Guide
  • Lubrication
• Dismantling/Assembling Instructions
  • Disassembling the Powerhead
  • Disassembling the Ratchet Link
  • Assembling the Powerhead
  • Assembling the Swivel Manifold
  • Filling Oil
  • Pressure Testing
  • Assembling the Ratchet Link
  • Testing the Assembly

Maintenance Instructions

• Service and Maintenance Recommendations
• Preventive Maintenance
• Overhaul Instructions

Service and Maintenance Recommendations

Always wear impact-resistant eye and face protection when involved with or near the operation, repair or maintenance of the tool or changing accessories on the tool.

All investigation, maintenance or repair work should only be carried out when the complete system is at zero pressure.

For optimum performance, frequently inspect tool, power pack, hoses, connectors, electric cables, and accessories for visual damage. Always follow instructions for tool and pump maintenance.

Service Interval Guidance

Regular lubrication and overhaul is recommended to make sure that the wrench remains in good working order. More frequent service intervals may be needed if used at high torque, high cycle rate or long tightening times. If the wrench is not working properly, immediately take it away for inspection.

The following service intervals are for guidance only. Each use case and application is different, so it is the responsibility of the end user to implement suitable planned maintenance specific to the working environment and usage.

Light Duty

Example: Infrequent use at low pressures, <40% capacity.

• Lubrication: every 6 months

• Overhaul: every 12 months

Normal Duty

Example: Regular use, <80% capacity.

• Lubrication: every 3 months

• Overhaul: every 12 months, including drive pin replacement. See section Assembling the Ratchet Link.

Heavy Duty

Example: Constant use at any pressure; use >80% Capacity; regular use to loosen corroded bolts.

• Lubrication: every 1 month

• Overhaul: every 6 months, including drive pin and drive pawl replacement. See section Assembling the Ratchet Link.

Use in ATEX Zones

Use the Heavy Duty guidelines regardless of duty to greatly reduce the risk of component failure when in use. If the wrench shows signs of malfunction, remove it from the ATEX zone before investigating the cause. DO NOT attempt to repair the wrench in the ATEX zone. Failure to comply with the maintenance recommendations will increase the likelihood of mechanical failure and therefore the chance of mechanical spark generation.

High Pressure Hose

• Hoses should be disassembled regularly. The fittings and adaptors must be inspected for wear and damage. If wear or damage is found during maintenance, the affected part must be removed and replaced.

• Examine the hoses for traces of oil that will indicate a slow leak on the hose. Pay close attention to the swages on both ends of the hose as these are the most common areas for oil leaks. If a slow leak is discovered, replace the hose.

• Always clean and coil hose after every use. Wipe the hoses with a clean cloth and spray with a suitable rust inhibitor oil such as Shell Ensis or Castrol Rustillo.

• Do not bend hose over obstructions or use the hose to move attached equipment.

• Pressure test the hoses every second year, and replace hose sets after six years.

Preventive Maintenance

To keep the hydraulic torque wrench system in good working condition, do the following maintenance steps after each period of use.

Overhaul Instructions

Lubrication Instructions

• Lubricant Guide
• Lubrication

Lubricant Guide

Lubrication

To keep the wrenches in good working condition, lubricate the drive components periodically between service intervals.

Disassembly before lubrication:

Do the following actions during lubrication maintenance:

The procedure for assembly is the same as for disassembly but backwards.

Dismantling/Assembling Instructions

• Disassembling the Powerhead
• Disassembling the Ratchet Link
• Assembling the Powerhead
• Assembling the Swivel Manifold
• Filling Oil
• Pressure Testing
• Assembling the Ratchet Link
• Testing the Assembly

Disassembling the Powerhead

Disassembling the Ratchet Link

The procedure for disassembly is the same as for assembly, but backwards. See section Assembling the Ratchet Link.

Assembling the Powerhead

Assembling the Swivel Manifold

The Torcflex wrench can be fitted with 2 types of swivel manifold. Follow the instructions below to replace or change the manifold when needed.

Use Loctite 243 as thread locker to prevent loosening on assemblies.

Installing a Co-axial Swivel Manifold

Installing a Twin-line Swivel Manifold

Filling Oil

Pressure Testing

Assembling the Ratchet Link

Testing the Assembly

Troubleshooting

• Troubleshooting

Troubleshooting

Recycling

• Environmental Regulations

Environmental Regulations

When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle the components in accordance with local legislation.