Torque Multipliers, Models 1U-7293, 6V-7820 and 6V-6080{0599, 0765} Caterpillar

Caterpillar Products: All

Introduction

European Union Compliant, CE Marked

Important Safety Information

Illustration 1	g02139237
Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2	g02166423
Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

General Information Section

Illustration 3	g03204460

Description and Design Features

Input and output rotation directions are the same (For example, clockwise input rotation creates clockwise output rotation). Torque multipliers use planetary gear action to tighten or loosen with a continuous 360° rotation in either clockwise or counterclockwise direction. On Model 6V-6080 only, an internal bi-directional anti-backlash device inhibits accidental torque wind-up release.

Note: Reaction force is equal to output force and is in the opposite direction of input/output rotation force.

Reaction bars are held in place using a detent pin or socket head cap screw, depending on the model.

On Models 6V-7820 and 6V-6080, a controlled-shear output square drive protects internal components in the event maximum output capacity is exceeded. This overload-protection feature causes the drive to fracture when output exceeds from 3% to 10% of rated output capacity. One replacement controlled-shear drive is included with both models.

On model 1U-7293 only, the square drive is an integral part of the torque multiplier gear cage assembly. This model has no overload protection feature.

A selector pawl on model 6V-6080 controls the torque multiplier rotational direction for manually applied input. The selector pawl is not present on other models.

An approved non-impact power drive may be used with Model 6V-6080 only. Refer to section on Pneumatic Operations for additional information.

Torque Conversions

A data plate attached to the torque multiplier displays input torque required to obtain listed output torque values. To calculate a specific input value not listed on the data plate, divide the desired output torque by the multiplier torque ratio. Refer to the section on Specifications for multiplier torque ratio.

Specifications

Table 1

Model Numbers		1U-7293	6V-7820	6V-6080
Output Capacity		750 Ft lb (1020 Nm)	1200 Ft lb (1627 Nm)	3200 Ft lb (4340 Nm)
Input Capacity		250 Ft lb (339 Nm)	200 Ft lb (271 Nm)	173 Ft lb (234 Nm)
Gear Ratio		4:1	6.33:1	20.25:1
Torque Ratio		3:1	6:1	18.5:1
Accuracy		±5% of reading from 20% to 100% of full scale rating
Input Drive Female Square Size	Length S1	0.5 In (13 mm)	0.5 In (13 mm)	0.5 In (13 mm)
Output Drive Male Square Size	Length S2	0.75 In (19 mm)	0.75 In (19 mm)	1.0 In (25.4 mm)
Overall Dimensions	Length A	8.53 In (217 mm)	19.56 In (497 mm)	19.6 In (498 mm)
	Gearbox ø B	2.81 In (71 mm)	3.94 In (100 mm)	4.06 In (103 mm)
	Height C	3.25 In (83 mm)	4.0 In (102 mm)	6.5 In (165 mm)
Net Weight		4 Lb (1.8 kg)	9.1 Lb (4.1 kg)	18.3 Lb (8.3 kg)
Planetary Gear Stages		One	One	Two
Needle Bearings		No	Yes	Yes
Angle-of-Turn Protractor		No	Yes, 5° increments	Yes, 5° increments
Torque Conversion Chart		No	Yes	Yes
Shearable Replaceable Output Drive		No	Yes	Yes
Selector Pawl, CW/Neutral/CCW		No	No	Yes
Anti-Backlash Device		No	No	Yes
Power Drive Compatible		No	No	Yes

Reaction Arm and Square Drive

Illustration 4	g03204859

1. Reaction Bar

2. Socket Head Cap Screw

3. Torque Multiplier

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

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

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

Torque Multiplier Dimensions

Illustration 5	g03204968

Input End Details (Model 6V-6080 Only)

Illustration 6	g03206139

1. Rotational direction indicators

2. Neutral positioning set screw

3. Selector pawl

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

4. 1/2 inch female input square drive

Reaction forces increase closer to the multiplier

Illustration 7	g03206221

Note: Forces shown above are general examples only to demonstrate typical differences in force. Refer to section for multiplier output capacities applicable to models 1U-7293, 6V-7820, and 6V-6080.

Minimize bending moments created by the torque multiplier's reaction

Illustration 8	g03206337

Keep reaction anchor perpendicular to the reaction point.

Illustration 9	g03206477

Note: A torque multiplier with reaction plate is shown in the illustration above. The same instructions and precautions are applicable to torque multipliers equipped with a reaction bar.

Operation

Instructions

1. When positioning the torque multiplier, be sure the socket attached to the output is positioned so that the reaction bar is at a right angle to the fastener. Torque reaction creates a rotational force in the opposite direction from which input force is applied. Refer to Application Information section for additional torque multiplier reaction information.

2. DO NOT apply more torque than the application can withstand. Breakout torque can be greater than input torque. Allow a minimum of 50% additional tool capacity for breakout torque. Damaged and corroded fasteners can require even greater breakout torque capacity.

3. Monitor input torque using a torque wrench. If torque multiplier is used without a torque wrench, remember that output torque is significantly greater than the input torque.

Show/hide table



Illustration 10	g03206221

4. Prolong torque multiplier life. Maintain the shortest possible couple distance between the torque multiplier output and the fastener being addressed. Maintain the longest distance possible between the torque multiplier and the reaction point as possible.

Show/hide table



Illustration 11	g03206139

5. Model 6V-6080 Only: When using a POWER driven input, lock selector pawl (3) in neutral position using the neutral positioning set screw (2). Refer to Pneumatic Operation section for additional information.

6. Protect your warranty. Use only approved output square drives and replacement parts.

Manual Operation (All Models)

1. Read and understand all of the safety precautions included in the Safety Section of this manual.

Show/hide table



Illustration 12	g03204859

2. Connect the reaction anchor tube to the torque multiplier (3) using the capscrew (2) or detent pin (6) .

Show/hide table



Illustration 13	g03206139

3. Model 6V-6060 only: Set desired rotation direction by pushing the selector pawl (3) in the direction indicated by the letters and the directional arrows (1) stamped on the input end of the case. Example: "CCW" for counter-clockwise rotation. Push pawl to the end of travel in the direction shown by the "CCW" arrow. For clockwise rotation, push pawl in the opposite "CW" direction.

Show/hide table



Illustration 14	g03204859

4. Mount the proper size female square drive socket onto the torque multiplier's output square drive (4,5). Position socket and the torque multiplier (3) on the fastener to be tightened.

Show/hide table



Illustration 15	g03206477

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

   Note: When socket is properly positioned on fastener, reaction bar must be at right angles to the fastener to which torque is being applied.

6. Mount a 13 mm (1/2 inch) ratchet adapter and torque wrench (user-supplied) into the input of the torque multiplier.

7. To tighten using a torque wrench: Determine the proper input torque required. (Refer to torque data plate on the tool or refer to the specification table.) Output torque accuracy requires an accurate torque wrench in series with the torque multiplier. Apply torque with torque wrench until the desired input torque is achieved.

8. To remove torque multiplier from fastener: Model 6V-6080 only: Using a torque wrench, apply enough input torque to release internal anti-backlash device. Maintain torque input and push selector pawl into opposite position. (Example: Pawl set in "CW" position requires reset to "CCW" position.) Slowly relax input torque.

   Models 1U-7293 and 6V-7820 only: Apply torque to desired rating. Slowly relax input torque and remove multiplier from application.

9. To loosen using a torque wrench: Replace the torque wrench with a work handle. Models 1U-7293 and 6V-7820: Apply torque in the opposite direction until fastener is loose.

   Model 6V-6080 only: Follow same procedure as for tightening except set the selector pawl in the opposite position.

Pneumatic Operation (Model 6V-6080 only)

An approved non-impact power drive may be used with Model 6V-6080 only.

Illustration 16	g03206139

Selector pawl must be set in neutral position and the neutral position set screw must be tightened (2) to lock the selector pawl (3) for power drive unit operation.

When set in the proper position, the selector pawl WILL NOT move in either direction when the neutral position set screw is tightened.

Make sure that the power drive is set to deliver no more than the maximum allowable input torque. When equipped with an air pressure regulator, torque output can be controlled.

Models 1U-7293 and 6V-7820 are not designed for use with a power drive. Do not use a power drive with these models.

Replacing a Square Drive Assembly

Model 1U-7293

Illustration 17	g03219617

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

1. Remove retaining ring and circular shims from the input side of the torque multiplier housing.

2. Remove gear cage assembly from the ring gear (torque multiplier housing). The output square drive is an integral part of the gear cage assembly.

3. Remove input pinion from gear cage assembly with a pulling and twisting motion. Use an arbor press to remove dowel pins from the planet gears.

4. Replace gear cage assembly with new tool.

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

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

7. Reassemble input pinion and install assembly into ring gear (torque multiplier housing). Reassemble shims and retaining ring.

Model 6V-7820

Illustration 18	g03219861

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

1. Insert a prying tool under the retaining ring and remove it from the groove in the output gear cage. Remove the old square drive.

2. Insert the new square drive.

3. Install the new retaining ring into the groove in the output gear cage.

Model 6V-6080

Illustration 19	g03219964

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

1. Remove the O-Ring located on the face of the square drive carrier.

2. Remove the square drive retaining pin from the output drive carrier. Pull out the old square drive.

3. Insert retaining pin in output drive carrier. Be certain that the pin engages the hole in the replacement square drive.

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

Application Information

Torque Multiplier Reaction

There are many different ways of absorbing torque multiplier reaction forces. Although the methods are as varied as the applications, there are common practices that should be considered.

1. First consider the size and type of torque tool required for the application. Survey space limitations as well as the maximum torque needed. Allow a minimum of 50% additional capacity in the tool for breakout torque.

   Note: Damaged and corroded fasteners can require even greater breakout torque capacity. Allow a minimum of 100% over the make-up torque for these conditions. Example: Corroded studs and a 1.36 N·m (1,500 lb ft) make-up torque. Choose a tool with a capacity of at least 4.07 N·m (3,000 lb ft) for breakout.

Show/hide table



Illustration 20	g03206221

2. Select a solid anchor point to minimize deflection. Determine where the reaction forces are going to take place, for example, against a flange or over an adjacent bolt.

   This point must withstand the torque tool reaction forces. Example: A 3,200 Ft lb torque multiplier, with reaction near the end of the anchor stub produces a reaction force of about 28290.7 N (6360 lb). The reaction force can be reduced to about 10675.7 N (2400 lb) by moving the reaction point toward the end of the reaction bar. Keep the reaction point tangent to the rotation of the torque output to prevent increased reaction forces.

Show/hide table



Illustration 21	g03206337

3. Keep output torque rotation pure by reducing bending moments. Bending moments decrease torque efficiency and increase stress on the tool and sockets. Keep the distance between the tool output and the fastener as short as possible.

Show/hide table



Illustration 22	g03206477

4. Increase tool life and increase working environment safety by taking torque reaction as far out on the reaction anchor as possible.

Angle of Turn Protractor

Models 6V-7820 and 6V-6080 include an angle of turn protractor. This feature allows the operator to accurately measure a specific number of degrees of rotation of the fastener. The torque/angle of turn method of tightening fasteners requires a pre-torque value and a specific additional rotation of the fastener that is engineered into the application. This data will be supplied by the original equipment manufacturer's engineering department if angle of turn torquing is applicable.

Maintenance Section

Inspection

1. Inspect tooling prior to each use for dents, cracks, bent, or worn parts. If damage is found, destroy the tool and dispose of as scrap. Replace with new product.

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

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

Cleaning

Clean the tooling using a non-solvent based cleaner.

Storage

Store the tooling in a clean, dry location to prevent rust or corrosion. The tool should also be stored in the most stable position.

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

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

International: 1-309-578-7372

Email: dealerservicetool_hotline@cat.com