W2
RSL TOOLS
Operation and Maintenance
Manual
HEX WRENCH
SET
Document Ref:
Revision:
Revision Date:
W-ENG-5525-056
AD
Aug. 2012
SQUARE DRIVE WRENCH
SET
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
TABLE OF CONTENTS
SECTION
1
Page
SAFETY
3
1.0 - RSL TOOL SAFETY
1.1 – GENERAL SAFETY
1.2 – RSL TOOL SAFETY – PUMP TAG
3-4
4
5
SPECIFICATIONS
6
2.0 - SQUARE DRIVE (SQ. DR.) TOOLS
2.1 – HEX BITS FOR SQUARE DRIVE TOOLS
2.2 – HEX WRENCH
2.3 – NOMINAL OUTPUT TORQUE VS. PRESSURE TABLE
6
7
8-9
10
3
WRENCH DESCRIPTION
11
4
RSL TERMS & BOLTING CALCULATIONS
11-14
5
PLANNNING
14-16
6
OPERATING INSTRUCTIONS
16
2
6.0 – FLANGE ASSEMBLY & DISASSEMBLY
6.1.0 – CHOOSE FLANGE ASSEMBLY METHOD
6.1.1 – FLANGE DISASSEMBLY (LOOSEN)
6.1.2 – FLANGE ASSEMBLY EXAMPLE
6.2 – HEX TOOL REACTION
6.3 – SQUARE DRIVE TOOL REACTION
6.4 – OPERATING INSTRUCTIONS
7
WARRANTY, MAINTENANCE, & ASSEMBLY
7.1 – WARRANTY
7.2 – POWER HEAD MAINTENANCE
7.3 – POWER HEAD ASSEMBLY, TESTING, & DISASSEMBLY
7.4 – HEX & SQUARE DRIVE WRENCH MAINTENANCE
8
TROUBLE SHOOTING
22
22
22
22-23
23
24
8.0 – TABLE
8.1 – GENERAL HYDRAULIC
9
16
16
16
17
17-18
18-20
20-22
24
25
PART NUMBERS AND DRAWINGS
9.0 – POWER HEAD
9.0 – HEX WRENCH
9.0 – SQ. DR. WRENCH
9.0 – REACTION ARM
9.0 – SEAL KITS
26
26-27
28
29
30
31
10
TORQUE, FLANGE, & BOLT REFERENCE
32-37
11
TOOL ACCESSORIES
37
12
NOTES
38-39
WARRANTY
40
This tool, when used in conjunction with specified pump and hoses, conforms to
requirements for CE Marking. Contact Hydratight for a list of approved
components.
W-ENG-5525-056 (rev. AD)
Page 2 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 1.0 - RSL TOOL SAFETY


When RSL tools (with high force/torque, high pressure fluid/air, and electricity) are used they require operator:
o Adhere to strict safety procedures and operating instructions
o Accept primary responsibility for safety.
o Do not rush the job!
HYDRATIGHT offers free videos and training. This manual and additional safety related services are designed to:
o Assist in proper personnel training for use and care of RSL tools.
o Help prevent accidents and improve safety.
Operator must read, understand, and comply with all operating instructions prior to and during RSL
operation! Failure to do so may result in severe or fatal injury.
Hydratight highly recommends that one properly trained person hold and control operation of tool.
When two-person operation cannot be avoided:

A risk assessment must be performed that fully addresses specific application, communication, and
coordination of tool operation between two users.

Person HOLDING wrench must control operations and give command to energize pump.
Set-up proper tool reaction!

Incorrect set-up, or socket size, may cause tool, socket, nut, etc. to fracture and injure operator.

Cocking (socket fitting over nut at angle) is most common cause of socket fracture.
High hydraulic pressure hazard, 10,000 psi (690 bar)!

Use proper tools, hoses, fittings and protective equipment.

Keep clear of leaking hydraulic fluid. Immediately repair/replace tool, hoses, etc.

Never exceed maximum working pressure marked on power head.
Immediately replace damaged hoses.

Damaged hoses may release hydraulic fluid under pressure and cause injury.

Do not expose hoses to damaging conditions!

Hose damage may result from mechanical, thermal, or chemical abuse.

Do not use hoses as a lift strap when lifting or moving tool
Maintain equipment in good working condition!

Inspect for cracks/wear.

Immediately replace damaged parts and remove damaged equipment from service.

Lubricate moving parts with SWEENEY 503 lubricant.

Check for loose parts prior to operation
Electrical:

Follow proper lockout and tag procedures (include all power supplies) before performing
maintenance!

Identify and eliminate all electric hazards. Do not use frayed or damaged electrical cords.

Electric pump:
o Do not use in explosive or wet environments!
o Make sure grounding, power supply, and extension cord meet all appropriate electrical
codes.
Wear safety glasses!

Eye protection is necessary when working with or near our tool or hydraulic system.

Always use correct personal protective equipment (PPE) such as: safety harness, ear plugs (hearing
protection), hard hat, steel toe shoes, high visibility clothing, gloves, hair restraints, and coveralls.
Keep clear of pinch points!

Keep hands, fingers, etc. clear of reaction area and other tight spaces with moving parts.
W-ENG-5525-056 (rev. AD)
Page 3 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 1.0 - RSL TOOL SAFETY (continued)
Never position yourself in line with equipment under tension or pressure.

Stay clear of potential projectiles.
Do not subject any equipment, tool, or accessory to impact!
Do not modify tool!

Unauthorized modifications may cause injury.

Contact HYDRATIGHT for special tool applications or modifications.
Tool is a potential fall hazard when used overhead. To avoid a fall hazard:

Securely tie tool off to a fixed object, and (as needed) secure socket to square drive with pin and ring.

Securely attach reaction arm to power head with reaction arm’s locking device (e.g. dialock).

Operator’s hazard analysis may determine that reaction arm must be further retained. Contact
Hydratight for Bulletin 116, which shows how to properly tie reaction arm to power head with a cable.
Always assess risks and mitigate hazards
SECTION 1.1 - GENERAL SAFETY
Protect yourself against a fall. Use proper equipment & follow proper procedures when working at
height.
Do not use tool while tired or under the influence of drugs, alcohol, or medication.
Work with a valid permit when required.
Do not walk under a suspended load.
Follow site smoking rules as required.
 Work site:
o Keep work site clean.
o Maintain adequate work space.
o Clear area of flammable substances.
 Keep loose clothing, long hair, or any other unsecured parts away from operating machines.
 If a power failure occurs, set control valves and switches to proper position.
Valves are typically “closed” and switches are typically “off”.
W-ENG-5525-056 (rev. AD)
Page 4 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 1.2 - RSL TOOL SAFETY – PUMP TAG



RSL tools are powered by an electric or air powered hydraulic pump.
Attach safety tag (below) to pump to ensure operator has important safety and operating instructions.
Refer to pump’s manual for the pump’s safety and operating instructions.
OPERATOR MUST READ
AND UNDERSTAND
ENGAGEMENT
BEFORE USING EQUIPMENT
ROTATE ARM
INSTEAD OF
LIFTING
INCORRECT REACTING
WILL CAUSE HIGH STRESS
ON TOOL AND SOCKET,
MAY RESULT IN POSSIBLE
BREAKAGE AND INJURY
90°
COCKING
HIGH HYDRAULIC
AVOID ANY
ANGULAR
ENGAGEMENT
USE WITH PROPER
690 BAR
10000 PSI
TOOLS AND HOSES
IS RECOMMENDED
NEVER REACT
IN REVERSED
POSITION
DO NOT STRIKE
HEX WRENCH HEADS
PINCH POINTS.
90°
ANY EQUIPMENT
AVOID ANY
ANGULAR
ENGAGEMENT
LEADING THE WAY
IN BOLTING TECHNOLOGY
DO NOT
REACT
ON SPLINE
90°
NO ANGULAR
ADJUSTMENT
ALLOWED.
IN LINE
REACTION
ONLY
RSL-STAG-REV A
SIDE 1
W-ENG-5525-056 (rev. AD)
SIDE 2
Page 5 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 2.0 - SPECIFICATIONS - SQUARE DRIVE TOOLS
TABLE 2.0-1
Square Drive Dimensions and Specifications
Square
Drive
Model
Max Output
Torque
Weight
Square
Drive
Size
W
W1
H
L
L1
R
Power Head
Reaction
Arm
Sq. Dr.
Head
lb-ft
N-m
in
in
mm
in
mm
in
mm
in
mm
in
mm
in
mm
lb
kg
lb
kg
lb
kg
RSL2
1408
1909
0.75
1.25
32
2.30
58
4.48
114
6.29
160
7.45
189
0.94
24
3.4
1.55
1.0
0.45
2.8
1.27
RSL4
3080
4176
1.00
1.50
38
2.88
73
5.57
141
7.67
195
10.3
262
1.25
32
5.6
2.55
2.2
1.00
5.2
2.36
RSL6
5303
7190
1.50
1.75
45
3.71
94
6.42
163
9.27
235
11.67
296
1.52
39
8.9
4.05
4.0
1.81
9.1
4.14
RSL8
7862
10659
1.50
2.40
61
4.14
105
6.65
169
9.47
241
11.78
300
1.52
39
10.6
4.82
4.3
1.95
11.6
5.27
RSL14
11154
15123
1.50
2.50
64
4.63
118
7.93
201
11.2
284
12.4
315
1.88
48
11.6
5.27
6.6
3.00
18.4
8.36
RSL20
18843
25547
2.50
3.25
83
6.38
162
9.48
241
13.46
342
18.97
482
2.5
64
20.0
9.09
15.7
7.12
28.9
13.14
RSL30
28002
37965
2.50
3.50
89
6.54
166
10.35
263
14.09
358
21.07
536
2.5
64
22.0
10.00
11.1
5.03
39.3
17.86
W-ENG-5525-056 (rev. AD)
Page 6 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 2.1 – SPECIFICATIONS
HEX BITS (MALE HEX INSERTS) FOR SQ. DR. TOOLS
W-ENG-5525-056 (rev. AD)
Page 7 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 2.2 - SPECIFICATIONS - HEX WRENCH
TABLE 2.2-1
Hex Wrench Dimensions and Specifications
Max Torque
Output
Hex
Wrench
Model &
Housing
inch
(decimal)
inch
(fraction)
mm
lb-ft
N-m
inch
mm
inch
mm
inch
mm
inch
mm
RSL2H014
0.875
7/8
22
320
433.9
0.79
20.1
6.00
152.4
1.25
31.8
4.33
110
101
1.062
1 1/16
27
640
867.7
0.95
24.1
6.05
153.7
1.25
31.8
4.50
114.3
104
1.250
1 1/4
31
640
867.7
1.03
26.2
6.12
155.4
1.25
31.8
4.57
116.1
107
1.438
1 7/16
36
900
1220.2
1.15
29.2
6.24
158.5
1.25
31.8
4.69
119.1
110
1.625
1 5/8
42
1408
1909
1.31
33.4
6.41
162.8
1.25
31.8
4.86
123.4
113
1.813
1 13/16
46
1408
1909
1.40
35.5
6.49
164.8
1.25
31.8
4.94
125.5
200
2.000
2
50
1408
1909
1.48
37.7
6.58
167.1
1.25
31.8
5.03
127.8
203
2.188
2 3/16
55
1408
1909
1.58
40.1
6.68
169.7
1.25
31.8
5.13
130.3
206
2.375
2 3/8
60
1408
1909
1.70
43.2
6.79
172.5
1.25
31.8
5.24
133.1
RSL4H104
1.250
1 1/4
32
600
813.5
1.03
26.2
7.45
189.2
1.38
35.1
5.35
135.9
107
1.438
1 7/16
36
900
1220.2
1.18
30
7.62
193.5
1.38
35.1
5.49
139.4
110
1.625
1 5/8
41
1200
1627
1.32
33.5
7.77
197.4
1.38
35.1
5.63
143
113
1.813
1 13/16
46
1900
2576
1.47
37.3
7.87
199.9
1.38
35.1
5.78
146.8
200
2.000
2
50
2600
3525.1
1.60
40.6
8.04
204.2
1.38
35.1
5.92
150.4
203
2.188
2 3/16
55
3080
4175.9
1.76
44.7
8.16
207.3
1.38
35.1
6.08
154.4
206
2.375
2 3/8
60
3080
4175.9
1.84
46.7
8.25
209.6
1.38
35.1
6.15
156.2
209
2.562
2 9/16
65
3080
4175.9
1.95
49.5
8.14
206.8
1.38
35.1
6.26
159
212
2.750
2 3/4
70
3080
4175.9
2.04
51.8
8.23
209
1.38
35.1
6.36
161.5
215
2.938
2 15/16
74
3080
4175.9
2.16
54.9
8.34
211.8
1.38
35.1
6.54
166.1
RSL6H200
2.000
2
50
2600
3525.1
1.61
40.9
9.08
230.6
1.75
44.5
6.52
165.6
203
2.188
2 3/16
55
3500
4745.3
1.71
43.4
9.18
233.2
1.75
44.5
6.62
168.1
206
2.375
2 3/8
60
4500
6101.1
1.87
47.5
9.34
237.2
1.75
44.5
6.78
172.2
209
2.562
2 9/16
65
5303
7189.8
2.01
51.1
9.48
240.8
1.75
44.5
6.92
175.8
212
2.750
2 3/4
70
5303
7189.8
2.16
54.9
9.63
244.6
1.75
44.5
7.07
179.6
215
2.938
2 15/16
75
5303
7189.8
2.24
56.9
9.71
246.6
1.75
44.5
7.15
181.6
302
3.125
3 1/8
80
5303
7189.8
2.26
57.4
9.73
247.1
1.75
44.5
7.17
182.1
Max. AF Size
W-ENG-5525-056 (rev. AD)
R
L
Page 8 of 40
W
H
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 2.2 - SPECIFICATIONS - HEX WRENCH
TABLE 2.2-2
Hex Wrench Dimensions and Specifications
Max. Output
Torque
Hex
Wrench
Model &
Housing
in.
(decimal)
in.
(fraction)
mm
lb-ft
N-m
in.
mm
in.
mm
in.
mm
in.
mm
RSL8H203
2.188
2 3/16
55
3500
4745.3
1.71
43.4
9.37
238.0
2.25
57.2
6.84
173.7
206
2.375
2 3/8
60
4500
6101.1
1.87
47.5
9.53
242.1
2.25
57.2
7.00
177.8
209
2.562
2 9/16
65
5800
7863.6
2.10
53.3
9.67
245.6
2.25
57.2
7.13
181.1
212
2.750
2 3/4
70
7862
10659.3
2.16
54.9
9.82
249.4
2.25
57.2
7.28
184.9
215
2.938
2 15/16
75
7862
10659.3
2.24
56.9
9.90
251.5
2.25
57.2
7.36
186.9
302
3.125
3 1/8
-
7862
10659.3
2.26
57.4
9.92
252.0
2.25
57.2
7.39
187.7
302
-
-
80
7300
9897.3
2.26
57.4
9.92
252.0
2.25
57.2
7.39
187.7
RSL14H209
2.562
2 9/16
65
5800
7863.6
1.98
50.3
10.00
254.0
2.50
63.5
8.03
204.0
212
2.750
2 3/4
70
7300
9897.3
2.19
55.6
11.20
284.5
2.50
63.5
8.23
209.0
215
2.938
2 15/16
75
9000
12202.2
2.29
58.2
11.31
287.3
2.50
63.5
8.34
211.8
302
3.125
3 1/8
79
11154
15122.6
2.43
61.7
11.44
290.6
2.50
63.5
8.47
215.1
308
3.500
3 1/2
89
11154
15122.6
2.60
66.0
11.71
297.4
2.50
63.5
8.64
219.5
314
3.875
3 7/8
98
11154
15122.6
2.88
73.2
11.89
302.0
2.50
63.5
8.92
226.6
404
4.250
4 1/4
108
11154
15122.6
2.98
75.7
12.00
304.8
2.50
63.5
9.03
229.4
410
4.625
4 5/8
117
11154
15122.6
3.25
82.6
12.27
311.7
2.50
63.5
9.30
236.2
RSL20H302
3.125
3 1/8
79
11000
14913.8
2.45
62.2
12.72
323.1
2.75
69.9
9.44
239.8
308
3.500
3 1/2
89
16000
21692.8
2.77
70.4
13.04
331.2
2.75
69.9
9.76
247.9
314
3.875
3 7/8
98
18843
25547.3
2.95
74.9
13.22
335.8
2.75
69.9
9.94
252.5
404
4.250
4 1/4
108
18843
25547.3
3.30
83.8
13.57
344.7
2.75
69.9
10.28
261.1
Max. AF Size
R
L
W
H
410
4.625
4 5/8
117
18843
25547.3
3.44
87.4
13.71
348.2
2.75
69.9
10.43
264.9
RSL30H308
3.500
3 1/2
89
16000
21692.8
2.56
65.0
14.36
364.7
3.00
76.2
10.54
267.7
314
3.875
3 7/8
98
22000
29827.6
2.92
74.2
14.36
364.7
3.00
76.2
10.77
273.6
404
4.250
4 1/4
108
28002
37965.1
3.29
83.6
14.47
367.5
3.00
76.2
11.14
283.0
410
4.625
4 5/8
117
28002
37965.1
3.43
87.1
14.61
371.1
3.00
76.2
11.28
286.5
500
5.000
5
127
28002
37965.1
3.65
92.7
14.83
376.7
3.00
76.2
11.50
292.1
506
5.375
5 3/8
136
28002
37965.1
3.79
96.3
14.97
380.2
3.00
76.2
11.64
295.7
512
5.750
5 3/4
146
28002
37965.1
4.05
102.9
15.23
386.8
3.00
76.2
11.90
302.3
602
6.125
6 1/8
155
28002
37965.1
4.22
107.2
15.48
393.2
3.00
76.2
12.15
308.6
W-ENG-5525-056 (rev. AD)
Page 9 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 2.3 - SPECIFICATIONS
NOMINAL OUTPUT TORQUE VS. PRESSURE TABLE
TABLE 2.3-1
PRESSURE / TORQUE CONVERSION CHART FOR RSL TOOLS
PRESSURE
RSL2
RSL4
RSL6
RSL8
RSL14
RSL20
RSL30
PSI
BAR
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
1000
69
123
167
290
393
457
620
725
983
961
1303
1957
2653
2298
3116
1200
83
152
206
352
477
564
765
884
1199
1188
1611
2332
3162
2869
3890
1400
97
180
244
414
561
672
911
1043
1414
1414
1917
2708
3672
3440
4664
1600
1800
110
124
209
238
283
323
476
538
645
729
780
888
1058
1204
1201
1360
1628
1844
1641
1867
2225
2531
3083
3458
4180
4688
4012
4583
5439
6214
2000
138
267
362
600
813
995
1349
1518
2058
2094
2839
3822
5182
5154
6988
2200
152
296
401
662
898
1103
1495
1677
2274
2320
3145
4209
5707
5725
7762
2400
2600
165
179
324
353
439
479
724
786
982
1066
1211
1318
1642
1787
1836
1994
2489
2703
2547
2773
3453
3760
4584
4959
6215
6723
6296
6868
8536
9312
2800
193
382
518
848
1150
1426
1933
2153
2919
3000
4067
5334
7232
7439
10086
3000
207
411
557
910
1234
1534
2080
2311
3133
3226
4374
5710
7742
8010
10860
3200
221
439
595
972
1318
1641
2225
2470
3349
3453
4682
6085
8250
8581
11634
3400
3600
234
248
468
497
635
674
1034
1096
1402
1486
1749
1857
2371
2518
2629
2787
3564
3779
3679
3906
4988
5296
6460
6835
8758
9267
9152
9724
12408
13184
3800
262
525
712
1158
1570
1964
2663
2946
3994
4132
5602
7210
9775
10295
13958
4000
276
554
751
1220
1654
2072
2809
3104
4208
4359
5910
7586
10285
10866
14732
4200
290
583
790
1282
1738
2180
2956
3263
4424
4585
6216
7961
10794
11437
15506
4400
4600
303
317
611
640
828
868
1344
1406
1822
1906
2288
2395
3102
3247
3422
3580
4640
4854
4812
5038
6524
6831
8336
8711
11302
11810
12008
12579
16280
17055
4800
331
669
907
1468
1990
2503
3394
3739
5069
5265
7138
9087
12320
13151
17830
5000
345
697
945
1530
2074
2611
3540
3897
5284
5491
7445
9462
12829
13722
18604
5200
359
726
984
1592
2158
2718
3685
4056
5499
5718
7752
9837
13337
14293
19378
5400
5600
372
386
754
783
1022
1062
1654
1716
2242
2327
2826
2934
3831
3978
4215
4373
5715
5929
5944
6171
8059
8367
10212
10588
13845
14355
14864
15435
20153
20927
5800
400
811
1100
1778
2411
3041
4123
4532
6144
6397
8673
10963
14864
16007
21702
6000
414
840
1139
1840
2495
3149
4269
4690
6359
6624
8981
11338
15372
16578
22476
6200
6400
427
441
868
897
1177
1216
1902
1964
2579
2663
3257
3364
4416
4561
4849
5008
6574
6790
6850
7077
9287
9595
11713
12089
15880
16390
17149
17720
23251
24025
6600
6800
455
469
925
954
1254
1293
2026
2088
2747
2831
3472
3580
4707
4854
5166
5325
7004
7220
7303
7530
9901
10209
12464
12839
16899
17407
18291
18863
24799
25574
7000
483
982
1331
2150
2915
3688
5000
5483
7434
7756
10516
13214
17916
19434
26349
7200
7400
496
510
1011
1039
1371
1409
2212
2274
2999
3083
3795
3903
5145
5292
5642
5801
7649
7865
7983
8209
10823
11130
13589
13965
18424
18934
20005
20576
27123
27897
7600
7800
524
538
1068
1096
1448
1486
2336
2398
3167
3251
4011
4118
5438
5583
5959
6118
8079
8295
8436
8662
11438
11744
14340
14715
19442
19951
21147
21719
28671
29447
8000
552
1125
1525
2460
3335
4226
5730
6276
8509
8889
12052
15090
20459
22290
30221
8200
8400
565
579
1153
1181
1563
1601
2522
2584
3419
3503
4334
4441
5876
6021
6435
6594
8725
8940
9115
9342
12358
12666
15466
15841
20969
21477
22861
23432
30995
31769
8600
8800
593
607
1210
1238
1641
1678
2646
2708
3587
3672
4549
4657
6168
6314
6752
6911
9154
9370
9568
9795
12972
13280
16216
16591
21986
22494
24003
24575
32543
33319
9000
621
1266
1716
2770
3756
4764
6459
7069
9584
10021
13586
16967
23004
25146
34093
9200
634
1295
1756
2832
3840
4872
6605
7228
9800
10248
13894
17342
23512
25717
34867
9400
648
1323
1794
2894
3924
4980
6752
7387
10015
10474
14201
17717
24021
26288
35641
9600
9800
662
676
1351
1380
1832
1871
2956
3018
4008
4092
5087
5195
6897
7043
7545
7704
10230
10445
10701
10927
14508
14815
18092
18467
24529
25038
26859
27431
36415
37191
10000
689
1408
1909
3080
4176
5303
7190
7862
10659
11154
15123
18843
25547
28002
37965
1)
1 PSI = 6.894757 kPa
2)
1 PSI = .006894757 MPa
W-ENG-5525-056 (rev. AD)
3) 1 PSI = .06894757 Bar
Page 10 of 40
4) 1 Bar = 14.503774 PSI = .1 MPa
5)
1 lb*ft = 1.3558 N*m
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
SECTION 4.0 – RSL TERMS &
BOLTING CALCULATIONS
SECTION 3.0
WRENCH DESCRIPTION
1.
1.
2.
RSL square drive and hex tools are offered in
seven standard models:
3.
TABLE 3.0-1
MAXIMUM OUTPUT TORQUE
MODEL
4.
(LB*FT)
(N*M)
RSL2
1408
1909
RSL4
3080
4176
RSL6
5303
7190
RSL8
7862
10660
RSL14
11154
15123
RSL20
18843
25547
RSL30
28002
37966
Note: See Sections 2.0 & 2.2 for more details.
2.
3.
Global
Date: Aug. 2012
5.
6.
7.
See Section 4.0 for definitions of key terms.
RSL torque wrenches (tools):
a. Enable user to accomplish bolting tasks with
high torque, accuracy, and efficiency.
b. Are powered by hydraulic pump operated at
pressures:
i.
Up to 10000 psi (690 bar) for advance
stroke.
ii.
From 1500 to 1700 psi for retract stroke.
c. Apply a specific tension (tighten/makeup) to
studs, bolts and cap screws. It does this by:
i. Applying proper torque value for a specific
bolt material, bolt size, & lubricant.
ii. Refer to torque vs. pressure certificate of
precision for each tool, or Table 2.3-1 for
the nominal torque vs. pressure table.
iii. Desired fastener tension is achieved by:
1) Precisely controlling pump pressure
2) Use torque vs. pressure certificate of
precision for individual tool to apply
proper torque.
3) Controlling fastener frictional forces
between stud/nut, and nut/flange by:
- Use lubricant with known friction
coefficient on threads, nut face, etc.
- Bolts/nuts are not damaged or dirty
d. Are used to remove fastener tension
(loosen/breakout).
7.
8.
AF – Across Flat
Full torque hex wrench – A hex wrench with a
housing which is strong enough to be rated at the
maximum torque for a RSL series. See torque
rating in Table 2.2-1 and Table 2.2-2.
Male hex bit – Insert for a square drive tool which
replaces the square drive with a hex version.
Typically used on socket head cap screws. See
Table 2.1-1.
Reduced torque hex wrench - A hex wrench with a
housing which “is not” strong enough to be rated at
the maximum torque for a RSL series. See torque
rating in Table 2.2-1 and Table 2.2-2.
RSL - Ratcheting Slim Line
RSLxxSDS – RSL Square Drive Wrench Set
(e.g. RSL30SDS, RSL4SDS)
RSLxxHxxx – RSL Hex Wrench Set
a. RSLxxHxxx – RSL30H602 (RSL30 for a 62/16” or 6-1/8” AF Fastener)
b. RSLxxHxxM – RSL2H60M (RSL2 for a 60 mm
AF Fastener)
Torque – The tendency of a force to rotate an
object about an axis (twist). Force times distance
from object axis.
Torque vs. Pressure Certificate of Precision –A
torque vs. pressure table and curve for a given
power head & wrench assembly.
Pump (Console)
Swivel
Caution!
1.
2.
3.
Do not modify any equipment or
accessories.
Contact HYDRATIGHT for special
applications or modifications.
Unauthorized modifications may
cause injury and/or damage plus
invalidate warranty.
Swivels – Square Drive Wrench
FIGURE 4.0–1 TERMS
W-ENG-5525-056 (rev. AD)
Page 11 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 4.0 (continued)
Low Pressure
Retract Stroke
High Pressure
Advance Stroke
Hex Wrench Head
(RSLxxHxxxxxx)
Power Head
Low Pressure
Retract Stroke
High Pressure
Advance Stroke
QD’s for Power Head Hoses
CEJN
Hex Wrench Set
Square Drive
QD’s for Power Head Hoses
Screw Type w/ Relief Valve
Hex Bit
(Male Hex Insert)
Square Drive Wrench Head
(RSLxxS)
Reaction Arm
Insert, Hex
Square Drive Wrench Set (SDS)
FIGURE 4.0–3 TERMS
FIGURE 4.0–2 TERMS
W-ENG-5525-056 (rev. AD)
Page 12 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
SECTION 4.0 - TERMS & BOLTING
CALCULATIONS (CONTINUED)
Warning:
- The formula’s below include simplifications
& give estimates of torque, elongation, etc.
- Use formulas with care for critical applications.
- Refer to ASME PCC-1-2010 for more
information.
9. TENSION
a. To prevent bolted joint leaks, it is necessary to:
i. Generate evenly distributed clamp force
around joint.
ii. Generate clamp force greater than
operational loads.
iii. Keep stud tension stress (from clamp force
and operational loads) below stud material
yield strength.
b. Notes:
i. Create joint clamp force by generating stud
tensile load with:
1) Controlled torque applied to nuts
2) Controlled stud elongation
ii. Correct tension is established by equipment
manufacturer, and/or governing
codes/standards for a particular application.
iii. Tension can be expressed as:
1) Stud tensile stress
2) Percent stud material yield strength
3) Stud elongation
4) Nut rotation (degrees).
c.
Minimize variation in torque required for a given
stud tension:
i. Use lubricant with known friction coefficient.
ii. Periodically calibrate pump/gauge, &
regulate pump pressure.
iii. Perform regular torque vs. pressure
certificate of precision tests
11. ELONGATION TENSIONING & CALCULATIONS
a. Determine required stud or bolt elongation for
desired tension with:
Lte 
 Lbe
D  F* 

 E * As E * Ar 
b.

F  P
Rt * ft
* 

 Rn * fn 
12  6.283 cos(  / 2 )

Where:
T
= Torque required (lb*ft).
F
= Tension (Stud/bolt) required (lb).
P
= Thread Pitch (inch/thread)
Rt = Thread pitch radius. (in.) (Fig 4.0-4).
Formula is for fasteners with yield stress equal to
or less than 100000 psi
----------------------------------------------------------------
= Thread pitch dia. (in.) (Fig 4.0-4).
= Included thread angle (degrees) (Fig 4.0-4).
For UN or ISO threads β is typically 60°.
For β = 60°; cos (60°/2) = .866
Rn = Mean nut face radius. (in.) (Fig 4.0-2).
 D min .16238 
As  3.14159 * 

^2
n 
 2
Formula is for fasteners with yield stress greater
than 100000 psi
----------------------------------------------------------------
1.3 

Ar  .7854 * Db 
^2
n 

= Friction coefficient – threads.
= Friction coefficient – nut face.
W-ENG-5525-056 (rev. AD)
Where ( Refer to Fig. 4.04-4 & 4.04-5):
D
= Stud (bolt) elongation (inch (in.)).
Lbe = Body effective length (in.).
Lte = Thread effective length (in.).
Bolt: Lbe = Lb + h*Lh
Lte = Lt + g*Ln
Stud: Lbe = Lb
Lte = Lt1 + g*Ln1 + Lt2 + g*Ln2
Where:
Lb = Body length
h = Head Length Factor (.3 to .6 (.5 typ.))
Lh = Bolt Head Height
Lt, Lt1, Lt2 = Thread length
g = Nut Length Factor (.3 to .6 (.5 typ.))
Ln, Ln1, Ln2 = Nut Thickness
E = Stud (bolt) modulus of elasticity (lb/in^2).
(e.g. Typical Steel = 30000000 lb/in^2 (psi))
As = Stud (bolt) tensile area (in^2)
Ar = Thread root area (in^2)
Where:
-----------------------------------------------------------------
.9743 

As  .7854 * Db 
^2
n 

Dt
β
ƒt
ƒn
Torque required for stud tension will vary
significantly with changes in lubrication friction
coefficient. Changes may be from contamination,
using different lubrication, etc.
d.
10. TORQUE TENSIONING & CALCULATIONS
a. Frictional torque between stud/nut threads and
mating surfaces (e.g. nut face/flange) must be
known and controlled to determine torque amount
for desired stud (bolt) tension.
b. Determine required torque for desired stud (bolt)
tension with:
T 
Global
Date: Aug. 2012
---------------------------------------------------------------Db = Nominal stud (bolt) diameter (in.).
Dmin = Minimum pitch diameter (in.)
n = Threads per inch
Page 13 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
SECTION 4.0 - TERMS & BOLTING
CALCULATIONS (CONTINUED)
SECTION 5.0 - PLANNING
1.
Warning! Bolt joint failure can cause injury, death,
extensive damage, significant down time, etc. In
these critical applications our customers:
a. Implement a program where each tool has a
periodically generated torque vs. pressure
certificate of precision to account for tool wear.
b. Periodically check the bolt pre-load of installed
fasteners with Ultra-sonic or “other methods”.
c. Periodically re-check fasteners to ensure they
are not loosening after the equipment has been
in operation.
2.
When required bolted joint pre-load accuracy is high:
a. Hydratight’s wrench pressure calculations:
i.
Use our best customs and practices.
ii.
Have been reliable for many years.
b. Hydratight has learned thru experience with
many customers on many different applications
that achieving desired bolted joint pre-load is
greatly influenced by: joint component quality,
joint alignment, lubricant quality, assembly
procedures, and technician training.
c. If the requirements in 2.b. are met for normal
plant or machine conditions, accuracy of bolt
joint pre-load will range from ±10% to ±25%
(depending on application).
d. If greater accuracy than 2.c. is required,
Hydratight recommends calibrating tightening
process by measuring residual bolt load.
3.
Hydratight recommends hiring properly trained,
qualified, and certified Joint Assembly Technicians.
4.
Warning! Sections 5.0-1 thru 5.0-3 are extremely
important and must be included in planning bolted
joint assembly process. If you require assistance,
contact Hydratight.
5.
Tool application:
a. Controlled torque tightening.
b. Stud elongation tightening.
c. Loosen fasteners.
6.
Determine required torque:
a. The best method is to use equipment
manufacturer’s torque values and follow their
procedures.
b. Table 10.0-1 & 10.0-2 list torque values for
common ASTM A193 studs, lubricants, and
other conditions.
c. Warning! Your application must match table
conditions. If application does not match, go to
next step.
d. Use Hydratight’s BoltUp® website:
http://www.boltup.com/
FIGURE 4.0-4
STUD AND NUT DIMENSIONS
FIGURE 4.0-5
BOLT AND NUT DIMENSIONS
c.
d.
Determine stud (bolt) elongation by:
i.
Measure length before tension = L1
ii.
Measure length after tension = L2
iii.
Elongation = L2 – L1
iv.
If elongating by heat:
1) Measure length = L3
2) Apply load by:
a) Heat stud (bolt)
b) Turning nut against flange
c) Allow to cool (normally 24 hours)
3) Measure length = L4
4) Elongation = L4 – L3
v.
Measure blind hole elongation:
1) Drill flat-bottom hole along stud axis.
2) Measure hole depth before tension = L5
3) Measure depth after tension = L6
4) Elongation = L6 – L5
Calculate torque required to produce a given
elongation:
i.
Calculate force (FF) required for given
elongation (DD) using:
Lte 
 Lbe
FF  DD / 

 E * As E * Ar 
ii.
TT 
Global
Date: Aug. 2012
Calculate torque (TT) to produce force (FF)
using:

FF  P
Rt * f
* 

 Rn * f 
12  6.283 cos(  / 2 )

W-ENG-5525-056 (rev. AD)
Page 14 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
SECTION 5.0
PLANNING (cont.)
Contact Hydratight’s Customer Service. They
will determine proper torque free of charge.
Please have this information when you call
(Fig. 4.0-4 & Fig. 4.0-5):
i.
Lubricant type and friction coefficient.
ii.
One of the following. Desired stud (bolt):
1) Tensile stress (pounds per sq. in.)
2) % of material’s yield or tensile strength.
3) Tensile load (pounds force).
iii.
Grip length (Lg)
iv.
Stud (bolt):
a. Stud (bolt) nominal diameter (Db)
b. Lengths (L, Lb, Lc, Lg, Lh, Ls)
c. Threads per in. (n), or in. per thread (P)
d. Grade (B7, B8, B16 etc.).
e. Hollow stud’s inner diameter.
v.
Nut:
a. Size across flat (AF)
b. Thickness (Ln, Ln1, Ln2)
c. Type (regular hex, heavy hex, or other).
d. Grade
vi.
If stud elongation or nut rotation method is
used to measure tension, provide:
1) Required elongation
2) Required nut rotation
3) Thread length (Lt, Lt1, Lt2)
4) Effective length info. (Section 4.0-11).
vii.
Gasket material, type, size, etc.
f. Hydratight recommends sizing a tool for
loosening (breakout) which is:
i.
At least 1-1/2 to 2 times tightening torque.
ii.
Four times tightening torque for some
applications
Warning! To avoid injury or tool damage
do not exceed maximum torque rating.
ii.
Hex wrench tools are used when:
1) Limited overhead space & tool with
impact socket will not fit.
2) Lightest weight tool is required.
3) There are limited numbers of nut sizes.
4) Easy bolt-to-bolt change-over is
required.
5) Tight bolt patterns require small nose
radius.
6) Minimal tool deflection is required.
c. Different AF hex inserts are available for a given
hex wrench model & housing size.
e.
7.
Evaluate which tool should be used (square drive or
hex). See figure 5.0-1 and 5.0-2.
a. Sq. dr. tool with impact socket or male hex bit:
i.
See Table 2.0-1 for standard square drive
sizes and maximum output torque limits.
ii.
RSL square drive tools are used with 3/4" to
2-1/2" square drive impact sockets.
iii.
Square drive tools & impact sockets (or
male hex bits - Table 2.1-1) are used when:
1) Little space limitations exist.
2) Light weight tool required to reduce
technician fatigue.
3) Large quantity of fasteners tightened.
4) Maximum tool versatility required. For
a given torque range technician can
easily change sockets for different
fastener sizes.
5) Socket head cap screws (which require
male hex drives) are tightened.
b.
Hex tool:
i.
Table 2.2-1 and Table 2.2-2 list available full
& limited-torque hex wrench heads.
1) Maximum (max.) operating pressures
vary for limited torque hex wrenches.
2) Max. torque stamped on wrench.
3) Wrench head is rated for max. torque
when torque rating is not on wrench.
W-ENG-5525-056 (rev. AD)
Global
Date: Aug. 2012
8.
Plan tool reaction. Sect. 6.2 (Hex) and 6.3 (Sq. Dr.).
9.
Select tool:
a. Hydratight offers full torque and limited torque
wrench heads. Reduced torque rating is
marked on wrench housing.
b. Table 2.0-1, 2.1-1, 2.2-1, & 2.2-2 list ratings.
c. “Best Practice” method for selecting tool is to
size tool to operate from 3000 to 6000 psi. for a
given tightening torque (3000 to 5000 psi for high
usage applications)
i.
This general recommendation offers best
compromise for tool life, size, maintenance,
& operating cost.
ii.
Use Table 2.3-1 to select tool & determine
nominal operating pressure.
10. Select hydraulic pump.
a. Pump’s tool extend pressure must not exceed
10,000 psi (690 bar).
b. Pump’s tool retract pressure must be between
1500 to 1700 psi (103.4 to 117.2 bar)
c. If electric power cord is long, select proper cord
size to minimize voltage drop.
d. If hoses are long, contact Hydratight to check
pressure drop.
11. Check Oil:
a. Proper oil (Standard is Hydratight HF-101):
i. Temperature requirement
ii. Food grade
b. Fill console reservoir
c. Pre-fill tool
d. Pre-fill hoses
e. Eliminate air from oil lines
12. Check tool:
a. Service properly
i.
Properly cleaned
ii.
Properly lubricated
iii.
Inspect all components for cracks/wear and
repair as needed
iv.
Eliminate all oil leaks immediately
b. Ensure torque vs. pressure certificate of
precision is current. Perform test more
frequently when tool:
i.
Is used in critical applications.
ii.
Is operated in high torque/pressure range.
iii.
Has been used frequently.
iv.
Operates in a dirty environment with
abrasives such as sand.
Page 15 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 6.1.0
SECTION 5.0 - PLANNING (cont.)
CHOOSE FLANGE ASSEMBLY METHOD
TIGHTEN METHOD 1 – Follow equipment
manufacturer procedures
2. TIGHTEN METHOD 2 – Torque, Legacy CrossPattern Tightening Sequence & Bolt Numbering,
Single tool 8 bolt flange example - Fig. 6.1.2-1:
a.
Mark fasteners with chalk in clockwise direction
(1, 2, 3, 4, 5, 6, 7, & 8). These numbers are
outside large circle in Fig. 6.1.2-1 and
correspond to numbers in examples below
(e.g. 1-5-3-7-2-6-4-8).
b.
Mark correct tightening sequence on studs
(“1”, “2”, “3”, “4”, “5”, “6”, “7”, & 8”).
i.
This sequence is defined by example below
(e.g. 1-5-3-7-2-6-4-8).
ii.
These are “circled numbers” in Fig 6.1.2-1.
iii.
In this case “1” relates to 1, “2” to 5, “3” to 3,
“4” to 7, “5” to 2, “6” to 6, “7” to 4, & “8” to 8.
c.
Determine torque value for each stage of stud
tightening (Section 5.0- 6 & 4.0-10)
i.
First stage - limit to 30% of final torque.
ii.
Second stage - limit to 60% of final torque.
iii.
Third & Fourth stages - 100% of final torque.
d.
Tighten sequence:
i.
First, second & third stages: Cross-pattern
tighten sequence in Fig. 6.1.2-1 (b).
ii.
Fourth, and Final Stage:
1) Clockwise “adjacent bolt-to-bolt
tightening” Fig. 6.1.2-1 (c).
2) Continue until all nuts stop rotating.
1.
FIG. 5.0-1 - Square Drive Tool
3.
FIGURE 5.0-2 - Hex Tool
SECTION 6.0
OPERATING INSTRUCTIONS - FLANGE
ASSEMBLY & DISASSEMBLY
1.
2.
3.
Perform hazard analysis before starting work
If critical application, see Section 5.0 (1. thru 4.)
Ensure fastener contact surfaces & flanges have
been properly cleaned and examined
a. Flanges
i.
Surface finish, Scratches, Nicks, Burrs,
Flatness
ii.
Nut bearing surface – No paint or other thick
coating, Not scored
b. Fasteners:
i.
No rust, corrosion, burrs
ii.
Make sure bolt/nut will turn freely by hand
beyond position where it will come to rest.
Do not lubricate for this test.
iii.
Fastener replacement is always safe option
iv.
See ASME PCC-1-2010 for fastener
replacement guidelines
4. Ensure:
a.
Joint members are properly aligned
b.
Gasket is properly installed
c.
Lubrication of fastener working surfaces been
properly considered
W-ENG-5525-056 (rev. AD)
4.
TIGHTEN METHOD 3 – Stud Elongation Tightening
a. Determine torque value for proper elongation.
i.
Section 5.0- 6 & 4.0-11.
ii.
(or) Contact Hydratight Customer Service
b. Follow steps in TIGHTEN METHOD 2
c. After 4th stage, if studs are:
i. Short – increase torque & tighten until studs
are proper length.
ii. Long – loosen until studs are proper length.
d. Caution: Do not over-stretch studs because
joint parts may fail.
TIGHTEN METHOD 4 – Use Guidelines for Pressure
Boundary Bolted Flange Joint Assembly (ASME
PCC-1-2010).
SECTION 6.1.1
FLANGE DISASSEMBLY (LOOSEN)
1.
Use following when corrosion is present to minimize
required torque to allow lower pump pressure &
increase pump & tool life:
a. Apply SWEENEY 501 penetrating oil to nuts &
wait for 5 minutes (minimum).
b. Heat fastener for hard applications with severe
corrosion, high torque requirements, etc.:
i.
Consult with equipment manufacture
ii.
Take necessary safety precautions for high
temperatures (Flammable materials, proper
protective equipment, etc.).
iii.
Be safe, allow parts to cool.
Page 16 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Figure 6.1.2-1 Notes:
SECTION 6.1.1 (cont.)
2.
3.
Loosen all nuts 1/8 turn. To increase tool and pump
life set lowest pressure which consistently works.
a.
Cameron BOP Bonnet – loosen bolts in four
post pattern
b.
Other – loosen bolts sequentially from nut to nut
If torque required to initially loosen nuts was:
a.
Less than 150% of tightening torque, then
remaining tension may be fully removed from
each stud sequentially.
b.
Greater than 150% tightening torque, repeat 2.
c.
Warning! Stud or flange damage may occur
when all tension is removed from first stud
without loosening others. Damage occurs
because loosened stud’s load is transferred to
remaining studs.
SECTION 6.1.2
FLANGE ASSEMBLY EXAMPLE – METHOD 2
o
o
4 Bolt Flange
1-3-2-4
8 Bolt Flange
1-5-3-7-2-6-4-8
12 Bolt Flange
1-5-9-3-7-11-2-6-10-4-8-12
16 Bolt Flange
1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
20 Bolt Flange
1-13-5-17-9-3-15-7-19-11-2-14-6-18-10-416-8-20-12
28 Bolt Flange
1-13-21-5-17-9-25-3-15-23-7-19-11-27-214-22-6-18-10-26-4-16-24-8-20-12-28
32 Bolt Flange
1-17-9-25-5-21-13-25-3-19-11-31-7-29-1527-2-18-10-30-6-22-14-26-4-20-12-32-8-2416-28
SECTION 6.2
1.
2.
3.
4.
5.
6.
7.
8.
nd
Hex insert must be correct size across flat (AF)
Hex nut must have full nut thickness covered by hex insert
Hex wrench must be square to stud center line
Reaction surface must be parallel to reaction arm surface
Determine if thread is right hand (RH) or left hand (LH)
Determine if fastener will be loosened or tightened
a. Plan to place hex wrench head on nut for loosening.
b. Plan to place hex wrench head on nut for tightening
(See fig. 6.2-1 for RH thread).
Fig. 6.2–1 - Proper hex tool reaction with reaction arm.
a. Preferred reaction method is to use reaction arm.
b. Contact Hydratight Customer Service or Engineering
for special reaction arms, or spline covers.
c. Do not react at sharp angle on reaction arm.
i.
Arrows in fig. 6.2-2 (upper left) show this.
ii.
May cause damage to spline and/or reaction arm.
iii.
Contact Customer Service for these applications.
Figure 6.2-5 (top) shows a common reaction method. RSL
reacts on power head housing’s flat surface.
Warning! Do not react against power head splines
(Fig. 6.2-5 (bottom)). Use spline cover (RSLxx-700S)
to prevent damage.
9.
st
When bolt numbering is correct:

All bolts on right side of flange will be odd numbers
(e.g. “1”, “5”, “3”, & “7”).

Bolts on left will be even numbers.
For more application based procedures refer to:

Guidelines for Pressure Boundary Bolted Flange
Joint Assembly (ASME PCC-1-2010)

Hydratight Sweeny Joint Integrity Assurance
procedures.
HEX TOOL REACTION
Examples: Legacy Cross-Pattern Tightening
Sequence
(a) Marked up
8 Bolt Flange
Global
Date: Aug. 2012
“Bump Reaction”:
a. Figure 6.2-3 shows a proper “Bump Reaction”.
b. Most hex wrenches do not have reaction bumps.
c. Figure 6.2-4 shows a hex wrench without a “Bump” &
shows an improper reaction.
rd
(b) 1 , 2 , and 3 Stage
Cross-Pattern Sequence
(c) 4th & Final Stage Adjacent Bolt to Bolt
Sequence
FIGURE 6.1.2-1
LEGACY CROSS-PATTERN TIGHTENING
SEQUENCE FOR 8 BOLT CIRCULAR FLANGE
W-ENG-5525-056 (rev. AD)
FIGURE 6.2-1
PROPER REACTION FOR HEX TOOL WITH
REACTION ARM
(Reaction arm must be as shown)
Page 17 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 6.2 (continued)
HEX TOOL REACTION
PROPER REACTION
FIGURE 6.2-2
HEX TOOL REACTION WITH REACTION ARM
IMPROPER REACTION
DO NOT REACT ON SPLINE
FIGURE 6.2-5
HEX TOOL REACTION NO REACTION ARM
(Tighten Position for RH Threads)
SECTION 6.3
SQUARE DRIVE TOOL REACTION
FIGURE 6.2-3
PROPER HEX TOOL REACTION WITH
REACTION “BUMP”
1.
2.
3.
4.
FIGURE 6.2-4
IMPROPER HEX TOOL REACTION
DO NOT REACT ON HEX WRENCH HOUSING
(NO REACTION BUMP)
W-ENG-5525-056 (rev. AD)
Determine if fastener is right hand or left hand thread
Determine if fastener will be loosened or tightened
a.
Plan to place square drive (sq. dr.) wrench head on
nut for loosening (See figure 6.3-1 & 6.3-2).
b.
Plan to place square drive (sq. dr.) wrench head on
nut for tightening (See figure 6.3-1 & 6.3-2).
Fig. 6.3-1 & 6.3-2 show proper sq. dr. tool reaction. Arrow
by hose points to gap required for proper reaction.
Figure 6.3-3 shows improper sq. dr. tool reaction
a.
Improper reaction and/or incorrect socket size make
tool, socket, or nut vulnerable to fracture.
b.
Sq. dr. tool must use reaction arm. Contact
Hydratight engineering for special applications.
c.
Reaction arm should be at 90 degrees and extend in
same direction as sq. dr. If rotation is required,
rotation must not exceed 3 degrees. Angle in Fig.
6.3-1 (right) must be 87 to 90 degrees. If reaction
arm rotated more than 3 degrees:
i.
Life may be reduced
ii.
Components and/or socket may fracture
d.
Lifting (cocking) is when a socket fits over bolt at an
angle. It:
i.
Is a common cause of socket breakage
ii.
May occur when reaction arm:
1) Has small engagement & operator lifts
reaction arm over flange. This creates “out of
square” engagement.
2) Reacts against sloped surface
Page 18 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 6.3 (continued)
5.
6.
Check reaction with a floor test (Figure 6.3-2)
a.
Set complete tool assembly (with socket) on floor
b.
Push down on square drive retainer (down arrow) and
hold.
c.
Check clearance under reaction arm (left pointing
arrow)
i.
If gap, proper reaction
ii.
If no gap, improper reaction
d.
May perform test on actual applications. If no gap,
rotate arm in direction of sq. dr. until gap appears. Do
not rotate more than 3 degrees. Angle in Fig. 6.3-1
(right) must be 87 to 90 degrees.
Warning! If tool rises when load is applied do not
operate tool. Injury &/or tool damage may result.
DO NOT REACT SQ. DR. TOOL WITH ARM IN
DIRECTION SHOWN – SOCKET MAY FRACTURE
Requires a Gap
Contact Hydratight Customer Service or Engineering for
special reaction arms for non-standard applications.
FIGURE 6.3-3
IMPROPER SQ. DR. TOOL REACTION
Note: Arrow(s) point to required gap.
FIGURE 6.3–1 - PROPER REACTION
(RH THREADS - SQUARE DRIVE TOOL)
Push Here
LOOSENING
TIGHTENING
FIGURE 6.3–2 - PROPER REACTION
(RH THREADS – SQ. DR. TOOL)
W-ENG-5525-056 (rev. AD)
7.
Square Drive Reaction Arm Extensions - Reaction arms
are made from aluminum, stainless steel, & steel. Steel
reaction arms, part number RSLxx-S70, can have blocks
welded to them to extend their length. These rules apply:
a. Only weld HR 8620 (or equivalent) steel rectangular
blocks to reaction arm base.
b. Blocks:
i.
Block surfaces must be parallel with reaction arm
base surfaces.
ii.
No “ramps”, or angled edges, which may ride up
over reaction point.
c. Relationship of closest point on reaction arm to
wrench is critical. (See fig. 6.3-4) Follow this rule:
i.
If one unit of length (1 inch) down is added,
closest point on extension must move 1.4 units
(1.4 inch) away from wrench.
ii.
Remember 1.4 to 1!
d. Weld size is important.
i.
Welds must be made by a certified welder
ii.
Complete side-to-side penetration welds are
required.
e. Reactions arms made from ASTM A148 80/50 steel.
i.
These arms are easily welded & heat treatment
is not required.
ii.
Use Flux Core E71T-1 weld rod (or equivalent).
Warning!
i.
Follow these instructions so maximum allowable
torque is not reduced.
ii.
If you do not follow the 1.4 units back to 1 unit
down rule, contact Hydratight’s engineering
department for tool’s reduced torque rating.
iii.
Do not weld aluminum arms, or hollow stainless
steel reaction arms (Fig. 6.3-5).
iv.
If you have any concerns, please contact
Hydratight Engineering Department.
Page 19 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 6.3 (continued)
4.
(As needed) Assemble power head and wrench head.
a. Assemble hex or square drive wrench per fig. 6.4-1.
b. To assemble:
i.
Must move pawl driver to retract position as
shown.
ii.
Couple wrench head to power head by hooking
retractor pin into pawl driver groove.
iii.
Position wrench head on power head.
iv.
Verify pin still engages pawl driver groove.
v.
Secure wrench to power head. Torque long and
short bolts according to Table 6.4-1.
FIGURE 6.3-4
STEEL REACTION ARM EXTENSIONS
Do Not Weld
FIGURE 6.3-5
DO NOT WELD TO REACTION ARMS LIKE THIS
FIGURE 6.4-1
WRENCH & POWER HEAD ASSEMBLY
SECTION 6.4
OPERATING INSTRUCTIONS
1.
2.
3.
TABLE 6.4-1
Hydratight inspects all tools prior to shipment. However:
a. Inspect for tool damage, leaks, etc. before each use.
b. Verify that all parts are included.
c. Do not use hoses as a handle or lift strap when
lifting or moving tool.
Select proper tool and accessories (See section 5.0):
a. Torque rating
b. RSLxxSDS - Square drive wrench & power head
i.
Reaction arm, or other.
ii.
Square drive AF (across flat)
iii.
Male hex bit. Table 2.1-1 (for socket head cap
screws)
iv.
Socket (for hex head cap screws & nuts):
1) Fastener AF
2) Short or long
c. RSLxxHxxx – Hex wrench and power head
i.
Reaction arm, tube, sleeve, or other
ii.
Proper hex insert
(Hex Wrench) Change hex wrench insert for proper AF.
W-ENG-5525-056 (rev. AD)
Page 20 of 40
Power Head Bolt Torque
Long Bolts
Short Bolts
MODEL
Lb*ft
N*m
Lb*ft
N*m
RSL2
19
26
23
31
RSL4
35
48
45
61
RSL6
60
82
105
142
RSL6A
85
116
105
142
RSL8
170
231
210
285
RSL14
110
149
110
149
RSL20
90
122
90
122
RSL30
150
203
150
203
Notes:
1. Use lubricant (oil)
2. Similar bolts have different torque values
because required clamp loads vary
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
SECTION 6.4 (continued)
5.
g.
(As needed – sq. dr.) Change sq. dr. assembly
direction from tighten to loosen (or vice-versa):
a. Remove square drive retainer
i.
Pull on end of retainer to release ball detents
ii.
Remove square drive retainer assembly
b. Remove and reposition square drive
c. Assemble drive retainer
i.
Pull on end of retainer to release ball detents
ii.
Insert sq. dr. retainer assembly into sq. dr.
iii.
Push on end of retainer to engage ball
detents
6.
(As needed – sq. dr.) Assemble socket to sq. dr. &
secure socket to square drive with o-ring & pin.
7.
(As needed) Assemble reaction arm ass’y. to wrench.
a. Rotate dialock to allow reaction arm to slide on to
power head splines.
b. Slip reaction arm over power head splines until it
stops against o-ring.
c. Rotate dialock (any direction) to next “click” (60
degrees), to lock reaction arm in place.
d. Check dialock engagement - pull reaction arm.
e. Warning! Dialock must be in locked position
before using tool!
f. (As needed) Secure reaction arm ass’y. to power
head with safety cable. Sect. 1.0 – RSL Safety.
8.
Connect air or electrical power source to hydraulic
pump. See pump manual.
9.
Assemble twin hose to pump (1st) & tool (2nd) before
setting tool on application. Fig. 6.4-(2/3/4) & 8.1-1.
a. Each end of a twin hose will have one male and
one female quick connect fitting (QD).
b. Pump will have like male/female fittings.
c. Connect pump high pressure advance stroke
port to tool high pressure advance port.
d. Connect remaining low pressure ports.
e. Always use an odd number (1, 3, 5 …) of twin
hose assemblies to connect tool to pump.
f. CEJN QD assembly procedure (fig. 6.4-2):
i. Unscrew locking collar on female QD.
ii. Slide outside slide ring back. Snap male and
female fittings together.
iii. Release slide ring.
iv. Screw locking collar back against slide ring.
Relief Valve
Male QD
High Pressure Advance
Slide Ring
Female QD
Low Pressure Retract
Male QD
High Pressure Advance
W-ENG-5525-056 (rev. AD)
Threaded QD assembly procedure (fig. 6.4-3)
i. Pull female threaded collar back
ii. Insert male section into female section.
iii. Screw female collar onto male section until
collar solidly contacts male shoulder.
Female QD
Low Pressure Retract
Locking Collar
FIGURE 6.4 - 2
HOSE QD’s – CEJN TYPE
Global
Date: Aug. 2012
FIG. 6.4-3 - QD’s - THREADED TYPE
10. Purge all air from tool before returning to service.
Suggested method:
a. Connect Power Head to pump.
b. Place Power Head below pump
c. Extend piston to end of stroke.
d. Remove hoses from power head & connect
hoses together.
e. Turn pump on and run for one minute.
f. Repeat until rod extends & retracts smoothly.
11. Tighten or loosen fasteners in accordance with
instructions in Section 6.1.
a. TIGHTEN METHOD 1 - Follow equipment
manufactures procedures.
b. TIGHTEN METHOD 2 - Torque - Legacy CrossPattern Tightening Sequence & Bolt Numbering
System – One Tool
c. TIGHTEN METHOD 3 – Stud Elongation
d. TIGHTEN METHOD 4 – See Guidelines in
Pressure Boundary Bolted Flange Joint Ass’y.
e. LOOSEN (BREAKOUT)
f. Note: Power Head, Square Drive Wrench Head,
Socket & Reaction Arm can be moved as a unit.
g. Note: Remember fasteners are typically
tightened, or loosened, incrementally. e.g. All
fasteners are loosened 1/8 turn in a first pass.
12. Determine if fastener will be loosened or tightened.
Set-up tool on proper nut according to the following:
a. Tighten right hand threads: Place tool on nut so
tool advance stroke will rotate nut clockwise.
b. Loosen right hand threads: Place tool on nut so
tool advance stroke will rotate nut counterclockwise.
c. (As needed) Change square drive position to
loosen or tighten. See Section 6.4 – 5.
13. Reaction and tool leak check:
a. Check that reaction arm is in firm contact with
stationary object (e.g. nut, flange, or housing).
b. For new applications:
i.
Set pump pressure near zero to start.
ii.
Gradually increase pressure and carefully
watch tool for proper reaction and oil leaks
1) If tool reacts improperly (e.g. Lifts over
reaction point), re-do reaction setup
2) If tool leaks, repair leaks immediately
c. Set pressure to minimum required for
application to maximize tool life.
Page 21 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
3.
SECTION 6.4 (continued)
14. To tighten a single fastener:
a. Pressure adjustment:
i.
Best practice is to use minimum tool
pressure to extend tool life. Do not operate
tool at max. if a lower pressure will work.
ii.
For new applications set pump pressure
near zero to start
iii.
Gradually increase pressure and carefully
watch tool for proper reaction and oil leaks
iv.
If tool does not react properly (e.g. Lifts
over reaction point), re-do reaction setup
b. Depress & hold pendant control button until
power head makes complete advance stroke.
c. Release control button to retract power head
d. During process operator must ensure reaction
arm is in constant contact with reaction point.
i.
Follow all safety rules during this process
(Pinch points, high pressure hydraulic, …)
ii.
This prevents creation of a pinch point
between tool & reaction point
e. Continue process until tool stalls (Pawl does not
engage with another tooth on square driver).
f. Release pendant control button to retract power
head. Depress & hold control button one more
time to attempt to turn nut.
g. If nut does not turn, desired torque is achieved
with related stud tension.
NOTES:

Order all replacement fasteners from Hydratight

Use Hydratight HF-101 hydraulic oil

Assembly notes for all power heads:
o Before assembly:

Clean all components

Lubricate all surfaces with oil (especially seals).

Replace seals & wear rings as needed.
o Torque Zero Leak Plug to 80 ±4 lb*in (9 ±.5 N*m)

RSL2B, RSL4B, RSL6A, RSL8A, and RSL14B

Item 21, part number 936633 in Table 9.0-1
o Purge air from tool. See section 6.4 – 10.
o Spanner Wrench – See Section 11.0 – 15
1.
Disassemble –Model RSL2B, RSL4B, RSL6A, RSL8A,
RSL14B & RSL20 - With Front Cap
a. Position power head at mid stroke
b. Install mating QD’s to QD’s on power head.
c. Remove pin joining Retractor with Piston (or 10-24 x
1.5 socket head cap screw on RSL8).
d. Remove push block and retractor.
e. Use spanner wrench to remove front cap.
f. Pull piston straight out (use lowest pressure needed).
2.
Assemble – Model RSL2B, RSL4B, RSL6A, RSL8A,
RSL14B & RSL20 - With Front Cap
a. Install seals & wear band into front cap & piston as
needed
b. Slide front cap on rod until it contacts piston.
c. Press piston into power head bore until front cap
contacts internal threads. Do not press on spherical
radius surfaces.
d. Use spanner wrench to tighten front cap until firmly
seated (RSL4A and B models to 60 lb-ft).
e. Reinstall retractor, bronze block, and retractor pin
(RSL8 has a socket head cap screw which is
tightened to 40 lb*in, & use blue loctite).
3.
Test Power Head Assembly – All Models
a. Follow all applicable safety rules in Section 1.
b. Connect power head to console with hoses.
c. Place power head in protective container.
d. Advance & retract piston three times.
e. Make sure piston moves freely.
f. Advance piston and hold at 10,000 psi for 5 seconds.
g. Repeat 3. f. two more times.
h. Follow proper lockout & tag policy for console & tool
i. Check power head, hoses, fittings, etc. for leaks.
i. No leaks: Disconnect hoses.
ii. Leaks:
1) Fix leaks
2) Repeat test. Start at 3.a.
High Pressure Advance
SECTION 7.0 - WARRANTY,
MAINTENANCE & ASSEMBLY
7.1 WARRANTY – These items void tool warranty:
1.
2.
3.
4.
5.
6.
7.
8.
Failure to use Hydratight replacement parts
Inadequate or improper lubrication
Failure to replace worn or cracked parts
Operating tool at excessive pressure
Striking our tool with a hammer or other impact device
Tool modification
Improper reaction method
See our tool warranty for complete details.
7.2 POWER HEAD MAINTENANCE
1.
If seal has small leak, replace seal because of high
hydraulic pressure hazard. See Table 9.0-5 for seal kits.
2.
Clean & lubricate bronze block & pawl driver mating
surfaces. Use Sweeney 503 Moly Paste. Frequency:
a. Depends on work environment - increase frequency if
tool is exposed to sand or other abrasive material
b. Frequently with high operating pressure
c. Increased frequency lengthens tool life
W-ENG-5525-056 (rev. AD)
Before each use:
a. Inspect tool structure (including splines, power head,
reaction arm, etc.) for cracks, chips, galling, or
deformities. If irregularities are found, service or
replace immediately.
b. Check retractor, bronze block, & retractor pin for fit.
c. Clean hoses & hose quick couplers.
d. Confirm power head & wrench head are:
i. Properly engaged – Retractor pin is inserted
properly in pawl driver slot
ii. Secured properly with socket head cap screws.
Torque screws per Table 6.4-1.
7.3 POWER HEAD ASSEMBLY, TESTING, &
DISASSEMBLY.
Low Pressure Retract
FIGURE 6.4-4
POWER HEAD PORTS
Global
Date: Aug. 2012
Page 22 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
5.
SECTION 7.3 (continued)
4.
5.
Disassemble – Model RSL30
a. Position power head at mid stroke
b. Install mating QD’s to QD on power head.
c. Remove pin joining retractor with piston
d. Remove end cap bolts
e. Remove end cap
f. Pour out hydraulic oil.
g. Remove piston by pressing on its end. (Do not press
on spherical radius surfaces).
Assemble – Model RSL30
a. Install seals & wear rings into end cap, front cap, &
piston as needed
b. Insert piston into cylinder to end of stroke.
c. Fill to high pressure inlet hole with hydraulic oil.
d. Assemble end cap to power head.
i. Tighten 22 bolts to 22 lb*ft.
ii. Lubricate bolts with hydraulic oil.
Global
Date: Aug. 2012
Wrench Assembly:
a. Before assembly:
i. Replace worn, cracked, damaged, etc. parts
ii. Clean all components
iii. Lubricate all moving surfaces with SWEENEY
503 Moly Paste.
iv. Inspect pawl teeth engagement (fig. 7.3-2): It
is extremely important that pawl & square
driver (or hex insert) teeth are in precise
engagement.
b. Reverse wrench disassembly steps
STORAGE:
- Clean & lubricate tool if stored (not used) for 5 days or more.
SERVICE:
- Hydratight highly recommends customers have their tools
repaired by Hydratight or a Hydratight approved service
center.
7.4 HEX AND SQ. DR. WRENCH MAINTENANCE
1.
General cleaning, lubrication, & inspection guidelines:
a. During initial 8 hour break-in period clean, inspect &
lubricate wrench after 1 hour of use. Adjust frequency
(based on inspections) as needed for your application.
b. Frequency may be reduced if:
i.
Tool is not operated at full torque/pressure
ii.
And inspections reveal minimal wear
c. Increase frequency when tool is exposed to:
i.
Sand or other abrasive material
ii.
Salt spray, salt water, …
d. Increase frequency with:
i.
Higher operating pressure
ii.
Increased usage
e. Increased frequency lengthens tool life
2.
Check housing and all internal parts for cracks, chips,
deformities, and wear.
a. Immediately replace parts which have cracks, chips,
deformities, or excessive wear
b. Inspect: Square drive, square driver, pawl (fig. 7.3-1),
pawl driver, pawl holding spring(s), sq. dr. wrench
housing, hex wrench housing halves, fasteners, etc.
3.
Hex wrench disassembly:
a. Remove socket head cap screw joining hex wrench
housings.
b. Separate housing halves to expose ratcheting
assembly.
c. Inspect pawl teeth engagement (fig. 7.3-2): It is
extremely important that pawl & hex insert teeth
are in precise engagement.
4.
Square drive wrench disassembly:
a. Remove sq. dr. from sq. dr. housing. Section 6.4-5.
b. Remove ratcheting assembly through bottom of
square drive housing.
c. Inspect pawl teeth engagement (fig. 7.3-2): It is
extremely important that pawl & square driver
teeth are in precise engagement.
Inspect For
Cracks
FIGURE 7.3-1
PAWL INSPECTION
Pawl Teeth Must be in
Precise Engagement
with Square Driver or
Hex Insert Teeth
FIGURE 7.3-2
PAWL TEETH ENGAGEMENT
W-ENG-5525-056 (rev. AD)
Page 23 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 8.0
TROUBLE SHOOTING
TABLE 8.0-1
TROUBLE SHOOTING
PROBLEM
CAUSE
SOLUTION
Hydraulic fluid leaks from power head.
Power head seals are worn.
Replace power head seals
- Power head rod does not extend, or
retract.
- Pump gauge shows hydraulic
pressure.
- Pump is running.
1. Quick connect couplings are:
a. Improperly assembled.
b. Worn & not properly engaged.
2. Piston seal is worn & hydraulic
fluid is leaking past piston.
1. Clean & properly connect
couplings. Use pliers to tighten
screw-on type.
2. Replace worn couplings.
3. Change piston seal.
Power head rod does not fully extend
when tool is not mounted on a stud.
1. Low console fluid level.
2. Air in hoses.
1. Add proper hydraulic fluid. See
pump manual.
2. Remove air. Section 6.4-10.
- Power head rod will not extend at all.
- Pump gauge reads zero.
- Pump is running.
1. Air valve sticks due to:
a. Moisture, or dirt in air supply.
b. Valve corrosion.
2. Solenoid valve sticks.
1. See pump manual.
2. If possible, install valve upgrade.
3. Air valve:
a. Clean air valve.
b. Service air line filter
4. Solenoid valve:
a. Clean solenoid valve.
b. Check line voltage.
Tool operates backwards. Advance
stroke button retracts piston rod.
Quick couplings are reversed on
hoses, pump, or power head.
Properly install quick couplings.
Tool does not operate even though
pump is running & all connections are
properly connected.
1. Improper power head & wrench
assembly.
2. Retractor pin is sheared.
1. Assemble correctly.
2. Replace retractor pin.
Wrench operation sluggish &/or noisy.
Poor lubrication.
- Disassemble wrench.
- Clean & inspect
- Replace broken parts as needed
- Lubricate all moving surfaces.
Nut partially returns with socket when
power head retracts.
Torsion on stud is causing nut to
return with stud.
Properly lubricate stud & nut threads.
Nut rotates with socket for power head
extension & returns to starting position
on retraction
- Nut too loose & thread friction will
not overcome pawl spring.
- Tool loses “ratchet” capability.
Tighten nut sufficiently before using
tool
Nut does not rotate as many degrees
as wrench (or socket).
1. Tool is not level or perpendicular
to stud centerline (“out of square”
engagement).
2. Nut corners are rounded off.
3. Socket or hex insert is over-size
1. Reposition tool &/or reaction arm so
it is level & perpendicular to stud
centerline (perform “floor test”).
2. Replace nut.
3. Use smaller socket or hex insert.
W-ENG-5525-056 (rev. AD)
Page 24 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 8.1
GENERAL HYDRAULIC TROUBLE SHOOTING
FIGURE 8.1-1
GENERAL HYDRAULIC TROUBLE SHOOTING
W-ENG-5525-056 (rev. AD)
Page 25 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 9.0
Part Numbers & Drawings
Fig 9.0-1
RSL POWER HEAD
Notes:
1)
2)
3)
4)
5)
To order replacement parts specify: Tool Style, Model Number, Serial Number, Description, and Part Number (see part lists).
Order all replacement parts from Hydratight (see website).
For other tool models refer to original manual or contact Hydratight.
Available:
a) Spare Part Kit - Includes seal kit, QD’s (male & female), long & short screws, & retractor pins. e.g. RSLxx-SPK.
b) Seal Kit – Table 9.0-5.
503 moly paste lubricant is part number 100002813 for a 4 lb can
W-ENG-5525-056 (rev. AD)
Page 26 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
TABLE 9.0-1
RSL POWER HEAD PART LISTS
ITEM
DESCRIPTION
QTY
POWER HEAD MODELS AND PART NUMBERS
RSL2B
RSL4B
RSL6A
RSL8A
RSL14B
RSL20
RSL30
1
Housing, Power Head
1
RSL2-1A
RSL4-1A
RSL6-1A
RSL8-1A
RSL14-1A
RSL20-1
RSL30-1
2
Piston
1
RSL2-2A
RSL4-2A
RSL6-2
RSL8-2
RSL14-2B
RSL20-2
RSL30-2
3
Piston Seal
1
942348
942300
942355
942346
942304
942356
942327
4
Piston Wear Ring
1
942349
942301
942354
942347
942306
942360
942328
5
6
7
Front Cap
O-Ring (Front Cap)
Gland Seal
1
1
1
RSL2-3
A000282070001
942272
RSL4-3B
A000282076006
942361
RSL6-3
A000282080001
942364
RSL8-3
A000282086001
942359
RSL14-3A
A000282090001
942367
RSL20-3
A000282098001
942358
N/A
N/A
942362
8
Retractor
1
RSL2-5A
RSL4-5
RSL6-5
RSL8-5
RSL14-5B
RSL20-5
RSL30-5
9
Pin, Retractor
1
A000141183001
A000141183001
921152
921152
RSL14-55
921152
921152
10
11
12
Pin, (Inner)
Block, Bronze
Pin, Roll
1
1
1
N/A
RSL2-4A
A000141192001
N/A
RSL4-4
A000141194001
A000141185001
RSL6-4
A000141198001
A000141185001
RSL8-4
N/A
A000141165001
RSL14-4
A000141201001
A000141185001
RSL20-4
A000141203001
A000141185001
RSL30-4
A000141203001
13
Pin, Roll (or screw)
RSL14 - Pin in pin
1
2
N/A
A000141194001
RSL6-55
A000151769001
A000141221001
& A000141169001
A000141203001
A000141183001
14 (b) Short Bolt
2
A000151813001
A000151862001
916279
916268
916268
916281
916270
15 (b) Long Bolt
2
RSL2-6
RSL4-6
RSL6-6A
RSL8-6
RSL14-6
RSL20-6
RSL30-6
16
17
18
Hose, Black
Hose, Blue
QD, Male
1
X1-192 (qty 2)
936541
X1-422BLK (qty 1)
X1-422BLU (qty 1)
936541
X1-422BLK (qty 1)
X1-422BLU (qty 1)
936541
X1-422BLK (qty 1)
X1-422BLU (qty 1)
936541
X1-422BLK (qty 1)
X1-422BLU (qty 1)
936541
X1-422BLK (qty 1)
X1-422BLU (qty 1)
936541
X1-422BLK (qty 1)
X1-422BLU (qty 1)
936541
19
QD, Female
1
936543
936543
936543
936543
936543
936543
936543
20
Relief Valve
1
X1-21
X1-21
X1-21
X1-21
X1-21
X1-21
X1-21
Plug
Sign, Safety
Reaction Arm
23
Assembly
24 (a) Overlay, Console
1
2
936633
RSL-308
936633
RSL-308
936633
RSL-308
936633
RSL-308
936633
RSL-308
A000371564001
RSL-308
Not Available
RSL-308
1
RSL2-70A
RSL4-70A
RSL6-70
RSL8-70A
RSL14-70A
RSL20-70
RSL30-710
1
X1-18
X1-1
X1-15
X1-14
X1-5
X1-16
X1-6
25 (a) Model Plate
Hex Key - for short
27 (a)
screw
Hex Key – for long
28 (a)
screw
29 (a) Hex Key – for hex head
1
N/A
N/A
RSL6-100A
RSL8-100
N/A
N/A
RSL30-100
1
913007 (1/4)
913009 (5/16)
913012 (3/8)
913023 (1/2)
913021 (5/8)
913021 (5/8)
913022 (3/4)
1
N/A
N/A
N/A
N/A
913020 (1/2)
N/A
N/A
1
913001 (3/32)
913001 (3/32)
913003 (5/32)
913003 (5/32)
913005 (3/16)
913005 (3/16)
913005 (3/16)
30 (a) End Cap (not shown)
31 (a) End Cap Seal(s)
32 (a) End Cap Bolts
1
1
22
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
RSL30-3
942334&942335
A000151829001
33 (a) Gland Wear Ring
1
N/A
N/A
N/A
N/A
N/A
N/A
942326
21
22
Note: (a) - Not shown. (b) - See Section 6.4-1 for bolt torque specifications. (c) – Use Hydratight HF-101 Oil at Assembly
W-ENG-5525-056 (rev. AD)
Page 27 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
FIGURE 9.0-2 - RSL HEX WRENCH HEAD PARTS
TABLE 9.0-2
HEX WRENCH HEAD PART LISTS
ITEM
DESCRIPTION
QTY
RSL2H
RSL4H
RSL2HXXX-3
RSL4HXXX-3
HEX WRENCH MODELS AND PART NUMBERS
RSL6H
RSL8H
RSL14H
RSL8HXXX-3
RSL14HXXX-3
RSL20H
RSL30H
RSL30HXXX-3
PAWL
1
2
INSERT, HEX
1
RSL2HXXX-4
RSL4HXXX-4
RSL6HXXX-4
RSL8HXXX-4
RSL14HXXX-4
RSL20HXXX-4
RSL30HXXX-4
3
HOUSING, RIGHT SIDE
1
RSL2HXXX-10
RSL4HXXX-10
RSL6HXXX-10
RSL8HXXX-10
RSL14HXXX-10
RSL20HXXX-10
RSL30HXXX-10
4
HOUSING, LEFT SIDE
1
RSL2HXXX-11
RSL4HXXX-11
RSL6HXXX-11
RSL8HXXX-11
RSL14HXXX-11
RSL20HXXX-11
RSL30HXXX-11
5
DRIVER, PAWL S-ASS’Y
1
RSL2HXXX-20
RSL4HXXX-20
RSL6HXXX-20
RSL8HXXX-20
RSL14HXXX-20
RSL20HXXX-20
RSL30HXXX-20
SOC. HD CAP SCREW
1
A000152945001
A000152945001
A000151766001
A000151768001
A000151790001
A000151792001
A000151792001
7
SPRING
1
950291
950250
950250
950250 (QTY 2)
950255
950263
950263
8
WASHER
1
A000261235001
A000261235001
A000261237001
A000261237001
A000261243001
A000261243001
A000261243001
9
PLATE, SAFETY
1
RSLH-300
RSLH-300
RSLH-300
RSLH-300
RSLH-300
RSLH-300
RSLH-300
10
PLATE, MODEL
1
RSL2H-100
RSL4H-100
RSL6H-100
RSL8H-100
RSL14H-100
RSL20H-100
RSL30H-100
6 (a)
RSL6HXXX-3
RSL20HXXX-3
1
NOTE: REPLACE “XXX” IN PART NUMBERS WITH HEX SIZE IN “1/16” INCH (XXX=111=1-11/16) (E.G. RSL2 PAWL FOR 1-11/16”. A/F HEX – RSL2H111-3
(a) HEX KEY SIZE IS: 1) 5/32 FOR RSL2, RSL4, RSL6, & RSL8. 2) 3/16 FOR RSL14, RSL20, & RSL30.
W-ENG-5525-056 (rev. AD)
Page 28 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
FIGURE 9.0-3
RSL Square Drive Wrench Head Parts
Hex Bit (option)
(Page 7)
TABLE 9.0-3
RSL SQUARE DRIVE WRENCH HEAD PART LISTS
SQUARE DRIVE MODELS AND PART NUMBERS
ITEM
DESCRIPTION
QTY
RSL2SA
RSL4S
RSL6S
RSL8S
RSL14S
RSL20S
RSL30S
1
RSL2S-3
RSL4S-3
RSL6S-3
RSL8S-3
RSL14S-3
RSL20S-3
RSL30S-3
1 (2)
950291
950302
950250
950250 (2)
950255
950263
950263 (2)
1
PAWL
2
SPRING
3
HOUSING
1
RSL2S-10A
RSL4S-10
RSL6S-10
RSL8S-10
RSL14S-10
RSL20S-10
RSL30S-10
4
ASSEMBLY, PAWL DRIVER
1
RSL2S-20
RSL4S-20
RSL6S-20
RSL8S-20
RSL14S-20
RSL20S-20
RSL30S-20
5
DRIVE, SQUARE
1
TA2S-40
TA4S-40
TA6S-40
TA8S-40
TA14S-40
RSL20S-40
RSL30S-40
6
DRIVER, SQUARE
1
RSL2S-4
RSL4S-4
RSL6S-4
RSL8S-4
RSL14S-4
RSL20S-4
RSL30S-4
7
ASS’Y, RETAINER, SQUARE
1
TA2S-44
TA4S-44
TA6S-44
TA6S-44
TA14S-44
RSL30S-44
RSL30S-44
10
PLATE, MODEL
1
RSL2S-100A
RSL4S-100
RSL6S-100
RSL8S-100
RSL14S-100
N/A
RSL30S-100
11
SIGN, SAFETY
1
RSLS-300
RSLS-300
RSLS-300
RSLS-300
RSLS-300
RSLS-300
RSLS-300
W-ENG-5525-056 (rev. AD)
Page 29 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
RSL20-70
(Stainless
Steel)
RSL2 THRU RSL14
(Stainless Steel)
RSL30-710
(Aluminum)
FIGURE 9.0-4
RSL REACTION ARM PART LISTS
TABLE 9.0-4
PART LISTS, RSL REACTION ARM ASSEMBLY
REACTION ARM MODELS AND PART NUMBERS
ITEM
DESCRIPTION
QTY
RSL2-70A
RSL4-70A
RSL6-70
RSL8-70A
RSL14-70A
RSL20-70
RSL30-710
1
Arm, reaction
1
RSL2-710A
RSL4-710A
RSL6-710
RSL8-710A
RSL14-71A
RSL20-71
RSL30-711
2
Dialock
1
RSL2-724A
RSL4-724
RSL8-724
RSL8-724
RSL14-724
N/A
N/A
3
Spring, compression
1
950288
950288
950285
950285
950285
N/A
N/A
4
Ball
1
900006
900006
900005
900005
900005
N/A
N/A
5
Dowel pin
1
A000141004001 A000141014001 A000141025001 A000141026001 A000141026001
N/A
N/A
6
O-ring
1
A000282152001 A000282157001 A000282161001 A000282163001 A000282165001
N/A
N/A
7
Sign, safety
1
RSL-308
RSL-308
RSL-308
RSL-308
RSL-308
RSL-308
RSL-308
8
Lever, retention
1
N/A
N/A
N/A
N/A
N/A
RSL20-72
N/A
9
Lock, retention
1
N/A
N/A
N/A
N/A
N/A
RSL20-73
N/A
10
Set Screw
1
N/A
N/A
N/A
N/A
N/A
A000152767001
N/A
11
Washer
1
N/A
N/A
N/A
N/A
N/A
A000261434001
N/A
12
Spring, compression
1
N/A
N/A
N/A
N/A
N/A
950300
N/A
13
Screw
2
N/A
N/A
N/A
N/A
N/A
N/A
RSL30-712
14
Roll Pin, ¼” D x 5/8" L
1
N/A
N/A
N/A
N/A
N/A
N/A
A000141274001
15
Insert, thread
2
N/A
N/A
N/A
N/A
N/A
N/A
926085
W-ENG-5525-056 (rev. AD)
Page 30 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 9.0 - Part Numbers and Drawings
Seal Kits - Parts Lists and Seal Placement Guide
Notes:
1.
2.
3.
4.
Seal replacement requires proper procedures to disassemble & assemble power head. See Section 7.0.
Use table and drawing below as a seal placement guide.
RSLxx-SKX - Universal Seal Kit consists of all seals for each respective RSL model (Not Available (N.A.) for RSL14).
RSL4-SKV - Viton seals for special environment driven applications.
TABLE 9.0-5
POWER HEAD SEAL KITS
Item Number
Seal Kit
RSL Model
RSL2-SKRD
RSL2 (rev D)
RSL2
RSL2A
RSL2B
RSL4*
RSL4A
RSL4B
RSL4A
RSL6 (rev C)
RSL6
RSL6A
RSL8 (rev H)**
RSL8A
RSL14 (N.A.)
RSL14A
RSL14B
RSL20
RSL30 (rev L)
RSL30
RSL2-SK
RSL4-SK
RSL4-SKA
RSL4-SKB
RSL4-SKV
RSL6-SKRC
RSL6-SK
RSL6-SKA
RSL8-SKRH
RSL8-SK
RSL14-SK
RSL14-SKA
RSL14SKB
RSL20-SK
RSL30-SKRL
RSL30-SK
1
2
3
4
5
Piston
Seal
Piston
Wear
Ring
Rod Seal
Rod
Wear
Ring
Front Cap Seal
A000282015001
942348
942349
942300
942301
942370
942301
942355
942354
942346
942347
942304
942306
942356
942360
942327
942328
n/a
6
End
Cap
Seal
(groove)
n/a
n/a
n/a
n/a
942302
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
(N.A.)
7
End
Cap
Seal
(corner)
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
A000282026001
942359
Not Available (N.A.)
n/a
n/a
n/a
n/a
942299
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
(N.A.)
342367
n/a
A000282090001
n/a
n/a
942358
A000282084001
942362
n/a
A000282098001
n/a
n/a
n/a
n/a
942335
942334
942272
A000282019001
942361
942371
A000282023001
942364
942326
A000282070001
A000282026001
A000282076006
A000282026004
A000282080001
A000282086001
* RSL4 Models with End Cap - Hydratight highly recommends using RSL4-IT Installation Tool at assembly. RSL4-IT is sold
separately and not included in RSL4-SK.
** Some older RSL8 Front Caps are reworked and have two grooves (small in front and big in back). Use big groove and square
seal. Do not install both seals.
Seal placement guide
Seal installation (Where Needed)
FIGURE 9.0-5
POWER HEAD SEAL KITS
W-ENG-5525-056 (rev. AD)
Page 31 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 10.0 - BOLT TORQUE REFERENCE
TABLE 10.0-1
TORQUE VALUE FOR ASTM A-193 GRADE B7 STUDS
STRESS EQUAL TO 50% OF MINIMUM YIELD STRENGTH (IMPERIAL UNITS)
NOM.
BOLT
SIZE
Db
THD/IN
(UNC/
UNF)
n
MINIMUM
YIELD
STRENGTH
TORQUE (T) FOR SPECIFIED LUBRICANT (LB*FT)
BOLT
TENSION
LOAD
(ROOT
AREA)
Fr
STUD
ELONGATION
-3
(IN)
(THD/IN)
(PSI)
(LBS)
(IN/IN x 10 )
f – FRICTION COEFFICIENT (ft = fn)
SWEENEY
API
SA2
MACHINE
OIL
DRY
STEEL
ON
STEEL
0.110
0.100
0.120
0.150
0.200
503
504
505
506
507
SWEENEY
SWEENEY
SWEENEY
SWEENEY
0.060
0.090
0.100
0.75
10
105000
16226
1.750
97
134
147
160
147
172
210
272
0.875
9
105000
22499
1.750
154
214
235
255
235
275
335
436
650
1
8
105000
29556
1.750
229
319
349
379
349
409
499
1.125
8
105000
38928
1.750
331
464
509
553
509
598
731
953
1.25
8
105000
49588
1.750
459
647
710
773
710
836
1024
1338
1.375
8
105000
61537
1.750
616
873
958
1044
958
1130
1387
1815
1.5
8
105000
74774
1.750
805
1145
1258
1372
1258
1485
1825
2393
1.625
8
105000
89300
1.750
1028
1468
1615
1761
1615
1908
2348
3081
1.75
8
105000
105115
1.750
1289
1846
2032
2218
2032
2404
2961
3890
1.875
8
105000
122218
1.750
1591
2285
2516
2747
2516
2979
3673
4829
2
8
105000
140609
1.750
1936
2787
3071
3354
3071
3638
4489
5908
2.25
8
105000
181258
1.750
2768
4001
4412
4823
4412
5235
6468
8524
2.5
8
105000
227061
1.750
3808
5524
6096
6668
6096
7240
8956
11816
2.75
8
95000
251540
1.583
4597
6687
7383
8080
7383
8777
10866
14350
3
8
95000
302307
1.583
5979
8718
9631
10544
9631
11457
14195
18760
3.25
8
95000
357738
1.583
7613
11123
12293
13463
12293
14633
18142
23992
3.5
8
95000
417832
1.583
9520
13933
15404
16875
15404
18347
22760
30116
3.75
8
95000
482589
1.583
11720
17180
19000
20821
19000
22641
28101
37201
4
8
95000
552010
1.583
14236
20896
23116
25337
23116
27557
34217
45318
4.25
8
75000
494284
1.250
13490
19825
21937
24049
21937
26161
32496
43055
4.5
8
75000
556453
1.250
16023
23573
26090
28607
26090
31124
38674
51258
503 – MOLYBDENUM DISULFIDE BASED (FUNCTIONAL EQUIVALENT C670, MOLY – COTE G PASTE)
504 – MOLYBDENUM LEAD OXIDE AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C100)
505 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT N1000)
506 – NICKEL AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT NICKEL EASE N5000, NEVER – SEEZ NICKEL SPECIAL)
507 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C5A, NEVER SEEZ)
W-ENG-5525-056 (rev. AD)
Page 32 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 10.0 - BOLT TORQUE REFERENCE
TABLE 10.0-2
TORQUE VALUE FOR ASTM A-193 GRADE B16 STUDS
STRESS EQUAL TO 35% OF MINIMUM YIELD STRENGTH (IMPERIAL UNITS)
NOM.
BOLT
SIZE
Db
THD/IN
(UNC/
UNF)
n
MINIMUM
YIELD
STRENGTH
TORQUE (T) FOR SPECIFIED LUBRICANT (LB*FT)
BOLT
TENSION
LOAD
(ROOT
AREA)
Fr
STUD
ELONGATION
-3
f – FRICTION COEFFICIENT (ft = fn)
SWEENEY
API
SA2
MACHINE
OIL
DRY
STEEL
ON
STEEL
503
504
505
506
507
SWEENEY
SWEENEY
SWEENEY
SWEENEY
(IN)
(THD/IN)
(PSI)
(LBS)
(IN/IN x 10 )
0.060
0.090
0.100
0.110
0.100
0.120
0.150
0.200
0.75
10
105000
11358
1.225
68
94
103
112
103
120
147
191
0.875
9
105000
15749
1.225
108
150
164
178
164
192
235
305
1
8
105000
20689
1.225
160
223
245
266
245
287
350
455
1.125
8
105000
27249
1.225
232
325
356
387
356
418
512
667
1.25
8
105000
34712
1.225
321
453
497
541
497
585
717
937
1.375
8
105000
43076
1.225
431
611
671
731
671
791
971
1270
1.5
8
105000
52342
1.225
563
801
881
960
881
1040
1278
1675
1.625
8
105000
62510
1.225
720
1028
1130
1233
1130
1336
1643
2157
1.75
8
105000
73580
1.225
902
1292
1423
1553
1423
1683
2073
2723
1.875
8
105000
85552
1.225
1113
1599
1761
1923
1761
2085
2571
3380
2
8
105000
98426
1.225
1355
1951
2149
2348
2149
2547
3143
4136
2.25
8
105000
126881
1.225
1937
2801
3089
3376
3089
3664
4528
5967
2.5
8
105000
158943
1.225
2666
3867
4267
4668
4267
5068
6269
8271
2.75
8
95000
176078
1.108
3218
4681
5168
5656
5168
6144
7606
10045
3
8
95000
211615
1.108
4185
6102
6741
7381
6741
8020
9937
13132
3.25
8
95000
250417
1.108
5329
7786
8605
9424
8605
10243
12700
16795
3.5
8
95000
292482
1.108
6664
9753
10783
11813
10783
12843
15932
21081
3.75
8
95000
337812
1.108
8204
12026
13300
14574
13300
15848
19670
26041
4
8
95000
386407
1.108
9965
14627
16181
17736
16181
19290
23952
31722
4.25
8
85000
392132
0.992
10702
15728
17404
19079
17404
20754
25780
34157
4.5
8
85000
441453
0.992
12712
18702
20698
22695
20698
24692
30681
40665
503 – MOLYBDENUM DISULFIDE BASED (FUNCTIONAL EQUIVALENT C670, MOLY – COTE G PASTE)
504 – MOLYBDENUM LEAD OXIDE AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C100)
505 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT N1000)
506 – NICKEL AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT NICKEL EASE N5000, NEVER – SEEZ NICKEL SPECIAL)
507 – COPPER AND GRAPHITE BASED (FUNCTIONAL EQUIVALENT C5A, NEVER SEEZ)
W-ENG-5525-056 (rev. AD)
Page 33 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-1
AMERICAN PETROLEUM INSTITUTE (API) FLANGE SPECIFICATIONS
DIA - STUD DIAMETER (INCHES), NO - NUMBER OF STUDS, AND BCD - BOLT CIRCLE DIAMETER (INCHES)
FLANGE
SIZE
2,000 PSI
3,000 PSI
5,000 PSI
10,000 PSI
15,000 PSI
20,000 PSI
DIA
NO
BCD
DIA
NO
BCD
DIA
NO
BCD
DIA
NO
BCD
DIA
NO
BCD
DIA
NO
BCD
2-1/16
2-9/16
3-1/16
3-1/8
4-1/16
5-1/8**
5/8
3/4
3/4
7/8
1
8
18
8
8
8
5
5-7/8
6-5/8
8-1/2
10-1/2
7/8
1
1
7/8
1-1/8
1-1/4
8
8
8
8
8
8
6-1/2
7-1/2
9-1/16
7-1/2
9-1/4
11
7/8
1
1-1/8
1-1/8
1-1/4
1-1/2
8
8
8
8
8
8
6-1/2
7-1/2
9-1/16
8
10-3/16
11-1/2
3/4
7/8
1-3/8
1-1/8
1-1/8
8
8
8
8
8
6-1/4
7-1/4
11-5/16
10-3/16
11-13/16
7/8
1
1-1/8
1-3/8
-
8
8
8
8
-
6-7/8
7-7/8
9-1/16
14-1/16
-
1-1/8
1-1/4
1-3/8
1-3/4
-
8
8
8
8
-
9-1/16
10-5/16
11-5/16
14-1/16
-
7-1/16
1
12
11-1/2
1-1/8
12
12-1/2
1-3/8
12
15-7/8
1-1/2
12
16-7/8
1-1/2
16
16-7/8
2
16
21-13/16
9
1-1/8
12
13-3/4
1-3/8
12
15-1/2
1-5/8
12
15-1/2
1-1/2
16
18-3/4
1-7/8
16
21-3/4
-
-
-
11
1-1/4
16
17
1-3/8
16
18-1/2
1-7/8
12
19
1-3/4
16
22-1/4
2
20
28
-
-
-
13-5/8
1-1/4
20
19-1/4
1-3/8
20
21
1-5/8
16
23-1/4
1-7/8
20
16-1/2
2-1/4
20
30-3/8
-
-
-
16-3/4
1-1/2
20
23-3/4
1-5/8
20
24-1/4
1-7/8
16
26-5/8
1-78
24
30-9/16
-
-
-
-
-
-
18-3/4
20-3/4
-
-
-
2
20
31-5/8
2
-
20
-
31-5/8
-
2-1/4
-
24
-
36-7/16
-
-
-
-
-
-
-
21-1/4
1-5/8
24
28-1/2
2
20
29-1/2
2
24
34-7/8
2-12
24
40-1/4
-
-
-
-
-
-
26-3/4
1-3/4
20
37-1/2
2
24
39-3/8
-
-
-
-
-
-
-
-
-
-
-
-
** INACTIVE IN 2,000, 3,000 and 5,000 PSI FLANGES
W-ENG-5525-056 (rev. AD)
Page 34 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-2
AMERICAN NATIONAL STANDARD (ANSI) FLANGE SPECIFICATIONS
DIA - STUD DIAMETER (INCHES), NO - NUMBER OF STUDS, AND BCD - BOLT CIRCLE DIAMETER (INCHES)
FLANGE
SIZE
2
3
4
5
6
8
10
12
14
16
18
20
24
150
DIA
5/8
5/8
5/8
3/4
3/4
3/4
7/8
7/8
1
1
1-1/8
1-1/8
1-1/4
NO
4
4
8
8
8
8
12
12
12
16
16
20
20
300
BCD
4-3/4
6
7-1/2
8-1/2
9-1/2
11-3/4
14-1/4
17
18-3/4
21-1/4
22-3/4
25
29-1/2
DIA
5/8
3/4
3/4
3/4
3/4
7/8
1
1-1/8
1-1/8
1-1/4
1-1/4
1-1/4
1-1/2
NO
8
8
8
8
12
12
16
16
20
20
24
24
24
400
BCD
5
6-5/8
7-7/8
9-1/4
10-5/8
13
15-1/4
17-3/4
20-1/4
22-1/2
24-3/4
27
32
600
DIA NO BCD
5/8
8
5
3/4
8
6-5/8
7/8
8
7-7/8
7/8
8
9-1/4
7/8
12 10-5/8
1
12
13
1-1/8 16 15-1/4
1-1/4 16 17-3/4
1-1/4 20 20-1/4
1-3/8 20 22-1/2
1-3/8 24 24-3/4
1-1/2 24
27
1-3/4 24
32
W-ENG-5525-056 (rev. AD)
DIA NO BCD
5/8
8
5
¾
8
6-5/8
7/8
8
8-1/2
1
8 10-1/2
1
12 11-1/2
1-1/8 12 13-3/4
1-1/4 16
17
1-1/4 20 19-1/4
1-3/8 20 20-3/4
1-1/2 20 23-3/4
1-5/8 20 25-3/4
1-5/8 24 28-1/2
1-7/8 24
33
Page 35 of 40
900
DIA
7/8
7/8
1-1/8
1-1/4
1-1/8
1-3/8
1-3/8
1-3/8
1-1/2
1-5/8
1-7/8
2
2-1/2
NO
8
8
8
8
12
12
16
20
20
20
20
20
20
1,500
BCD
8-1/2
7-1/2
9-1/4
11
12-1/2
15-1/2
18-1/2
21
22
24-1/4
27
29-1/2
35-1/2
DIA
7/8
1-1/8
1-1/4
1-1/2
1-3/8
1-5/8
1-7/8
2
2-1/4
2-1/2
2-3/4
3
3-1/2
NO
8
8
8
8
12
12
12
16
16
16
16
16
16
BCD
6-1/2
8
9-1/2
11-1/2
12-1/2
15-1/2
19
22-1/2
25
27-3/4
30-1/2
32-3/4
39
ENG US
2,500
DIA NO BCD
1
8
6-3/4
1-1/4 8
9
1-1/2 8 10-3/4
1-3/4 8 12-3/4
2
8 14-1/2
2
12 17-1/4
2-1/2 12 21-1/4
2-3/4 12 24-3/8
-
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-3
MANUFACTURER’S STANDARDIZATION SOCIETY OF VALVE AND FITTINGS INDUSTRY, INC.
DIA - STUD DIAMETER (INCHES), NO - NUMBER OF STUDS, AND BCD - BOLT CIRCLE DIAMETER (INCHES)
PIPE
SIZE
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
150
300
400
600
900
DIA
NO
BCD
DIA
NO
BCD
DIA
NO
BCD
DIA
NO
BCD
DIA
NO
BCD
7/8
7/8
1
1-1/8
1-1/8
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-3/4
1-3/4
1-3/4
1-3/4
1-3/4
1-3/4
12
12
16
16
20
20
20
24
28
28
28
32
32
32
36
36
40
40
44
44
44
44
48
48
52
17
18-3/4
25-1/4
22-3/4
25
27-3/4
29-1/2
31-3/4
34
36
38-1/2
40-1/2
42-3/4
45-3/4
47-1/4
49-1/2
51-3/4
53-3/4
56
58-1/4
60-1/2
62-3/4
65
67-3/4
69-1/4
1-1/8
1-1/8
1-1/4
1-1/4
1-1/4
1-1/2
1-1/2
1-5/8
1-5/8
1-3/4
1-7/8
1-7/8
2
1-1/2
1-5/8
1-5/8
1-3/4
1-7/8
1-7/8
2
2
2-1/4
2-1/4
2-1/4
2-1/4
16
20
20
24
24
24
24
28
28
28
28
28
32
32
32
32
32
28
32
32
32
28
28
32
32
17-3/4
20-1/4
20-1/5
24-3/4
27
29-1/4
32
34-1/2
37
39-1/4
41-1/2
43-1/2
46
43
45-1/2
47-1/2
49-3/4
52
54
56-1/4
58-1/4
61
63
65
67
1-1/4
1-1/4
1-3/8
1-3/8
1-1/2
1-5/8
1-3/4
1-3/4
1-7/8
2
2
2
2
1-3/4
1-7/8
1-7/8
2
2
2-1/4
2-1/4
2-1/4
2-1/2
2-1/2
2-1/2
2-3/4
16
20
20
24
24
24
24
28
28
28
28
28
32
32
32
32
32
36
28
32
32
28
32
32
32
17-3/4
20-1/4
22-1/2
24-3/4
27
29-1/4
32
34-1/2
37
39-1/4
41-1/2
43-1/2
46
44
46-1/4
48-1/4
50-1/2
52-3/4
55-1/4
57-1/2
59-1/2
62-1/4
64-1/4
66-1/4
69
1-1/4
1-3/8
1-1/2
1-5/8
1-5/8
1-3/4
1-7/8
1-7/8
2
2
2-1/4
2-1/4
2-1/4
2-1/4
2-1/4
2-1/2
2-1/2
2-1/2
2-3/4
3
3
3
3-1/4
3-1/4
3-1/2
20
20
20
20
24
24
24
28
28
28
28
28
28
28
32
28
32
32
32
28
32
32
32
32
28
19-1/4
20-3/4
32-3/4
25-3/4
28-1/2
30-2/3
33
36
38
40-1/4
42-1/2
44-1/2
47
45-3/4
47-3/4
50-1/2
52-1/2
54-3/4
57-1/2
60
62
64-1/4
66-3/4
68-3/4
71-3/4
1-3/4
1-1/2
1-5/8
1-7/8
2
2-1/2
2-3/4
3
3
3-1/4
3-1/2
3-1/2
3-1/2
3-1/2
3-1/2
3-3/4
4
4
-
20
20
20
20
20
20
20
20
20
20
20
20
20
24
24
24
24
24
-
21
22
24-1/4
27
29-1/2
35-1/5
37-1/2
40-1/4
42-3/4
45-1/2
48-1/2
50-3/4
50-3/4
52-3/4
54-3/4
67-2/3
60-1/2
62-1/2
-
W-ENG-5525-056 (rev. AD)
Page 36 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
SECTION 10.2
STUD & NUT SIZE CROSS REF.
SECTION 11.0
TOOL ACCESSORIES & OPTIONS
TABLE 10.2-1
NUT/BOLT A/F vs. STUD SIZE
NUT / BOLT (A/F)
INCH
mm
1-1/8 RB
STUD / BOLT NOM. DIA.
INCH
mm
3/4
30
1-1/4 H
1-5/16 RB
20RB
3/4
7/8
34
36
1-7/16 H
1-1/2 RB
1-5/8 H
1-11-16 B
1-13/16 H
1-7/8 B
41
46
20H
24RB, 22H
7/8
1
1
1-1/8
1-1/8
1-1/4
50
2H
2-1/16 B
1-1/4
1-3/8
2-3/16 H
2-1/4 B
1-3/8
1-1/2
65
70
75
80
85
3-3/8 B
3-1/2 H
4-1/8 B
4-1/4 H
42RB
48RB
48H
56RB
100
105
2-1/2
2-1/2
2-3/4
2-3/4
110
4-1/2 B
64H
72RB
80RB
3
120
4-7/8 B
5H
QUICK RELEASE COUPLINGS (QD) – CEJN
4.
DUST COVER – SCREW TYPE QD
5.
REACTION ARM – WELDABLE STEEL
6.
REACTION ARM – SPECIAL
7.
REACTION BARS
8.
HEX BITS – SQUARE DRIVE WRENCH (TABLE 2.1-1)
9.
HEX INSERT – HEX WRENCH
10. HANDLES
12. CONSOLES – AIR OR HYDRAULIC
14. SOCKETS WITH RETAINING PIN & RING
15. WRENCH, SPANNER, FRONT CAP:
a.
b.
c.
d.
e.
f.
MODEL
RSL2
RSL4B
RSL6
RSL8
RSL14A & B
RSL20
PART NUMBER
RSL2-3TOOL
RSL4-3BTOOL
RSL6-3TOOL
RSL8-3TOOL
RSL14-3ATOOL
RSL20-3TOOL
16. COVER ASS’Y, PWR HD SPLINE (RSL00-700S):
72H
115
3.
56H
64RB
3
4-5/8 H
2.
MODEL
PART NUMBER
QTY.
a. RSL2
X1-202B
2
b. RSL4 thru 30
X1-200B
2
QUICK RELEASE COUPLINGS (QD) – SCREW TYPE
42H
2-1/4
2-1/4
90
95
SWIVEL – TWO WAY
13. REDUCED THICKNESS HEX WRENCH
36H
1-1/2
1-5/8
1-3/4
1-3/4
1-7/8
1-7/8
2
2
1.
11. BRACKET - HANGING
36RB
60
3-3/4 B
3-7/8 H
30RB, 27H
30H
55
2-3/8 H
2-9/16 H
2-5/8 B
2-3/4 H
2-13/16 B
2-15/16 H
3B
3-1/8 H
24H
Global
Date: Aug. 2012
a.
b.
c.
d.
e.
f.
g.
MODEL
RSL2
RSL4
RSL6
RSL8
RSL14
RSL20
RSL30
PART NUMBER
RSL2-700S
RSL4-700S
RSL6-700S
RSL8-700S
RSL14-700S
RSL20-700S
RSL30-700S
80H
3-1/4
3-1/4
130
5/1/4 B
90RB
3-1/2
135
5-3/8 H
90H
3-1/2
145
5-3/4 H
100RB
3-3/4
150
6B
6-1/8 H
R = REGULAR HEX,
B = BOLT OR CAP SCREW
100H
4
4
H = HEAVY HEX,
W-ENG-5525-056 (rev. AD)
Page 37 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 12.0 - NOTES
W-ENG-5525-056 (rev. AD)
Page 38 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
SECTION 12.0 – NOTES (Continued)
W-ENG-5525-056 (rev. AD)
Page 39 of 40
ENG US
Title: RSL Tool Operation and Maintenance Manual
Doc number: W-ENG-5525-056 Revision: AD
Global
Date: Aug. 2012
WARRANTY
Hydratight warrants to original purchaser only that product manufactured by it will be free
from defects in design, materials and workmanship for three years from date on which product is
delivered to original purchaser. EXCEPT AS STATED IN THIS LIMITED WARRANTY,
HYDRATIGHT DOES NOT MAKE AND DISCLAIMS ALL EXPRESS OR IMPLIED
WARRANTIES INCLUDING, BUT NOT LIMITED TO, MERCHANTABILITY OF PRODUCT, ITS
FITNESS FOR A PARTICULAR PURPOSE, ITS DESIGN, CONDITION, OR WORKMANSHIP.
Hydratight’s obligation under this warranty is limited to replacing or restoring (at Hydratight’s
election) any product that is returned intact to Hydratight, or to one of its authorized service stations
with transportation charges prepaid, within warranty period, and that is disclosed, to Hydratight’s
satisfaction, to be defective after its examination.
Original purchaser is responsible for maintaining and replacing field serviceable items such
as fuses, heater coils, filter elements and fluids. Field serviceable items are not warranted by
Hydratight. This warranty shall not apply to any product that has been:
-Repaired or altered outside of Hydratight factory or authorized service stations
-Subject to misuse, abuse, negligence or accident
-Improperly installed or misused. Proper installation and use defined by Hydratight instructions
furnished with product.
HYDRATIGHT WILL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES OF ANY CHARACTER AS A RESULT OF A BREACH OF ITS
LIMITED WARRANTY, INCLUDING WITHOUT LIMITATION: INCONVENIENCE,
TRANSPORTATION COSTS, LOSS OF PROFITS, PROPERTY DAMAGE OR LOST
PRODUCTION, WHETHER SUFFERED BY ORIGINAL PURCHASER OR ANY THIRD PARTY.
Hydratight’s maximum liability under any circumstances will be purchase price of product paid by
original purchaser. Hydratight neither assumes nor authorizes any person to assume for it any
other or greater liability in connection with sale of its products.
Any provision in this limited warranty, including any provision limiting or excluding legal
remedies or warranties or merchantability or fitness for purpose, is not applicable where expressly
prohibited by local law, but only to extent so prohibited.
Any action for breach of this warranty, regardless of legal theory of action, must be brought
within one year after date of breach.
Documentation of date of delivery to original purchaser is required with all requests for
warranty. Contact Customer Service for a “Return Material Authorization” (RMA) number and
shipping instructions. Products returned without an RMA number will not be accepted.
W-ENG-5525-056 (rev. AD)
Page 40 of 40
ENG US