Signs That A Hydraulic Torque Wrench Needs Maintenance Or Repairs
Hydraulic torque wrenches output extreme amounts of force and handle extreme amounts of pressure. As such, if the tool experiences failure during operation, it may put nearby workers at risk of severe (or fatal) injury. The equipment itself could also sustain irreparable damage.
The key to avoiding a potentially catastrophic outcome is on-time maintenance and, when needed, prompt repairs. Some maintenance tasks – primarily preventative maintenance – can be managed by an operator comfortable with the wrench. Occasionally, though, your hydraulic tools will require expert attention to ensure they remain efficient, safe and accurate.
What Are the Signs That It’s Time to Get a Hydraulic Torque Wrench Professionally Repaired?
Prior to total failure, a hydraulic wrench will show a few signs that it needs an immediate inspection. Those signs include:
There are noticeable signs of wear or damage
The torque wrench will pick up wear on reaction surfaces, and this wear is a principal cause of performance loss and torquing reliability. Such wear typically develops around the 100,000 cycle mark, though it may emerge sooner if the tool is subjected to consistent, heavy duty operation. If such wear, or any other signs of body damage, are apparent, it’s time to schedule an expert inspection.
Oil is leaking onto the wrench body
If oil is leaking onto the wrench body, it could be a sign of a failing seal. If not addressed, fluid leaks will cause issues with force application and could be damaging to any surfaces the fluid comes in contact with. Fixing a leak requires full disassembly of the wrench, which may be beyond the scope of what your operators are capable of handling.
Wrench has been subjected to harsh working conditions
If your wrenches have been used in extended, heavy-duty applications, or if they have been exposed to extreme or corrosive environments, they should be inspected more often and by an expert technician.
The Most Important Rule of Wrench Maintenance - Track Tool Usage
After tens of thousands of cycles, hydraulic wrenches may wear to the point where they no longer deliver consistent fastening results. At first, this may not be noticeable to operators, but it can still result in reduced fastening performance.
The surest way to mitigate loss of wrench efficiency is on-time maintenance and calibration. And to ensure that, your team will need to track its tools – in terms of usage and condition. It’s not necessary to track usage down to the cycle, but tracking the number of operating hours is recommended. It’s also a good idea to make any notes on performance or condition in your tool management system.
By tracking wrench usage, your organization will know exactly when calibration issues are most likely to emerge and be able to proactively schedule maintenance.
What a Round of Preventative Maintenance Looks Like
Preventative maintenance is critical for extending tool performance and reliability – and hydraulic torque wrenches are no different. If your technicians are confident in their ability to breakdown and reassemble your torque wrenches, then the following preventative maintenance steps are recommended:
- Consult with the manufacturer’s instructional manual – The first step in any preventative maintenance plan is to organize how that plan should be executed. That largely hinges on what’s included in the manufacturer’s instructional guide. This guide should provide recommended maintenance intervals and give your team an idea of where to begin.
- Check the tightness of any retaining hardware – In particular, check the tightness for the screws connecting the wrench body to the swivel head. This hardware is stressed during torquing operations and therefore requires occasional tightening. Failing to do so may result in a weak connection between the wrench and pump.
- Check for any hydraulic fluid leaks – Pressurize the wrench to its maximum operating pressure value (10,000 psi), in both advance and retract modes. While under pressure, look for any fluid leaks seeping onto the wrench body. This is also a good time to check for any leaks around the couplers and hose connections.
- Clean accessible components with a mild solvent – Most operators can disassemble their torque wrenches to a small extent. The tool’s instructional guide typically provides instructions on how to do so.
During disassembly, there are certain components to target for a cleaning. These include the drive shaft, button assembly, the housing guard (and the screws holding it on), ratchet lever assembly and pin, the ratchet, drive shoe, compression springs, and the wrench body. These parts should be cleaned with a mild solvent and allowed to dry completely. - Apply grease to bearing surfaces – Following a thorough cleaning, those components will need to be lubricated to protect any bearing surfaces. Lubrication is done using molybdenum grease, though it’s crucial to consult with your wrench manual to confirm.
Apply this grease to any bearing surfaces recommended in the manual, which may include the button assembly, wrench body (including the inside side plates), ratchet lever, and the square drive. Take care not to lubricate the drive shoe or ratchet teeth, as this will cause slippage and inconsistent fastening.
Any maintenance beyond this level of complexity should be trusted to a technician certified with your tool’s brand and model. Any mistakes during reassembly or component replacement may result in severe equipment failure, safety issues, and extended downtime.
A Hydraulic Power Expert Can Provide Full Repair and Calibration Services
Hydraulic torque wrenches are expected to perform within extremely tight tolerances for extremely important operations – be it aerospace, marine, energy or construction projects. Any slight calibration error or bit of wear can throw these sensitive operations off.
To ensure your hydraulic torque wrenches remain reliable, your organization will need to invest in on-time tool maintenance. A trusted hydraulic power expert can provide those critical maintenance services and perform full tool breakdowns and inspections. If your wrenches are showing any signs of wear, damage or calibration issues, your hydraulic expert can identify the source of the problem and provide replacement components for your tools.