RSL Tools Operation and Maintenance Manual: Hex Wrench Square Drive Wrench SET SET

W2
RSL TOOLS
Operation and Maintenance
Manual
HEX WRENCH SQUARE DRIVE WRENCH

SET SET
Document Ref: W-ENG-5525-056

Revision: AD
Revision Date: Aug. 2012
Title: RSL Tool Operation and Maintenance Manual Global
Doc number: W-ENG-5525-056 Revision: AD Date: Aug. 2012
TABLE OF CONTENTS
SECTION Page
1 SAFETY 3
1.0 - RSL TOOL SAFETY 3-4
1.1 – GENERAL SAFETY 4
1.2 – RSL TOOL SAFETY – PUMP TAG 5
2 SPECIFICATIONS 6
2.0 - SQUARE DRIVE (SQ. DR.) TOOLS 6
2.1 – HEX BITS FOR SQUARE DRIVE TOOLS 7
2.2 – HEX WRENCH 8-9
2.3 – NOMINAL OUTPUT TORQUE VS. PRESSURE TABLE 10
3 WRENCH DESCRIPTION 11
4 RSL TERMS & BOLTING CALCULATIONS 11-14
5 PLANNNING 14-16
6 OPERATING INSTRUCTIONS 16
6.0 – FLANGE ASSEMBLY & DISASSEMBLY 16
6.1.0 – CHOOSE FLANGE ASSEMBLY METHOD 16
6.1.1 – FLANGE DISASSEMBLY (LOOSEN) 16
6.1.2 – FLANGE ASSEMBLY EXAMPLE 17
6.2 – HEX TOOL REACTION 17-18
6.3 – SQUARE DRIVE TOOL REACTION 18-20
6.4 – OPERATING INSTRUCTIONS 20-22
7 WARRANTY, MAINTENANCE, & ASSEMBLY 22
7.1 – WARRANTY 22
7.2 – POWER HEAD MAINTENANCE 22
7.3 – POWER HEAD ASSEMBLY, TESTING, & DISASSEMBLY 22-23
7.4 – HEX & SQUARE DRIVE WRENCH MAINTENANCE 23
8 TROUBLE SHOOTING 24
8.0 – TABLE 24
8.1 – GENERAL HYDRAULIC 25
9 PART NUMBERS AND DRAWINGS 26
9.0 – POWER HEAD 26-27
9.0 – HEX WRENCH 28
9.0 – SQ. DR. WRENCH 29
9.0 – REACTION ARM 30
9.0 – SEAL KITS 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

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.

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”.

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 ENGAGEMENT

AND UNDERSTAND
ROTATE ARM
90°
BEFORE USING EQUIPMENT INSTEAD OF
LIFTING
INCORRECT REACTING
WILL CAUSE HIGH STRESS
ON TOOL AND SOCKET,
MAY RESULT IN POSSIBLE
BREAKAGE AND INJURY
COCKING
HIGH HYDRAULIC
AVOID ANY
USE WITH PROPER ANGULAR
690 BAR ENGAGEMENT
10000 PSI TOOLS AND HOSES
PINCH POINTS. NEVER REACT

IN REVERSED
IS RECOMMENDED POSITION 90°
DO NOT STRIKE HEX WRENCH HEADS

ANY EQUIPMENT
AVOID ANY
ANGULAR
ENGAGEMENT
LEADING THE WAY

IN BOLTING TECHNOLOGY DO NOT
REACT
ON SPLINE
NO ANGULAR
ADJUSTMENT
ALLOWED.
90° IN LINE
REACTION
ONLY
RSL-STAG-REV A
SIDE 1 SIDE 2

SECTION 2.0 - SPECIFICATIONS - SQUARE DRIVE TOOLS
TABLE 2.0-1
Square Drive Dimensions and Specifications
Weight
Square
Square Max Output
Drive W W1 H L L1 R Reaction Sq. Dr.
Drive Torque Power Head
Size Arm Head
Model
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

SECTION 2.1 – SPECIFICATIONS
HEX BITS (MALE HEX INSERTS) FOR SQ. DR. TOOLS

SECTION 2.2 - SPECIFICATIONS - HEX WRENCH
TABLE 2.2-1
Hex Wrench Dimensions and Specifications
Hex Max Torque
Max. AF Size R L W H
Wrench Output
Model & inch inch
Housing mm lb-ft N-m inch mm inch mm inch mm inch mm
(decimal) (fraction)
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

SECTION 2.2 - SPECIFICATIONS - HEX WRENCH
TABLE 2.2-2
Hex Wrench Dimensions and Specifications
Hex Max. Output
Max. AF Size R L W H
Wrench Torque
Model & in. in.
Housing mm lb-ft N-m in. mm in. mm in. mm in. mm
(decimal) (fraction)
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
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

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 110 209 283 476 645 780 1058 1201 1628 1641 2225 3083 4180 4012 5439
1800 124 238 323 538 729 888 1204 1360 1844 1867 2531 3458 4688 4583 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 165 324 439 724 982 1211 1642 1836 2489 2547 3453 4584 6215 6296 8536
2600 179 353 479 786 1066 1318 1787 1994 2703 2773 3760 4959 6723 6868 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 234 468 635 1034 1402 1749 2371 2629 3564 3679 4988 6460 8758 9152 12408
3600 248 497 674 1096 1486 1857 2518 2787 3779 3906 5296 6835 9267 9724 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 303 611 828 1344 1822 2288 3102 3422 4640 4812 6524 8336 11302 12008 16280
4600 317 640 868 1406 1906 2395 3247 3580 4854 5038 6831 8711 11810 12579 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 372 754 1022 1654 2242 2826 3831 4215 5715 5944 8059 10212 13845 14864 20153
5600 386 783 1062 1716 2327 2934 3978 4373 5929 6171 8367 10588 14355 15435 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 427 868 1177 1902 2579 3257 4416 4849 6574 6850 9287 11713 15880 17149 23251
6400 441 897 1216 1964 2663 3364 4561 5008 6790 7077 9595 12089 16390 17720 24025
6600 455 925 1254 2026 2747 3472 4707 5166 7004 7303 9901 12464 16899 18291 24799
6800 469 954 1293 2088 2831 3580 4854 5325 7220 7530 10209 12839 17407 18863 25574
7000 483 982 1331 2150 2915 3688 5000 5483 7434 7756 10516 13214 17916 19434 26349
7200 496 1011 1371 2212 2999 3795 5145 5642 7649 7983 10823 13589 18424 20005 27123
7400 510 1039 1409 2274 3083 3903 5292 5801 7865 8209 11130 13965 18934 20576 27897
7600 524 1068 1448 2336 3167 4011 5438 5959 8079 8436 11438 14340 19442 21147 28671
7800 538 1096 1486 2398 3251 4118 5583 6118 8295 8662 11744 14715 19951 21719 29447
8000 552 1125 1525 2460 3335 4226 5730 6276 8509 8889 12052 15090 20459 22290 30221
8200 565 1153 1563 2522 3419 4334 5876 6435 8725 9115 12358 15466 20969 22861 30995
8400 579 1181 1601 2584 3503 4441 6021 6594 8940 9342 12666 15841 21477 23432 31769
8600 593 1210 1641 2646 3587 4549 6168 6752 9154 9568 12972 16216 21986 24003 32543
8800 607 1238 1678 2708 3672 4657 6314 6911 9370 9795 13280 16591 22494 24575 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 662 1351 1832 2956 4008 5087 6897 7545 10230 10701 14508 18092 24529 26859 36415
9800 676 1380 1871 3018 4092 5195 7043 7704 10445 10927 14815 18467 25038 27431 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 3) 1 PSI = .06894757 Bar 4) 1 Bar = 14.503774 PSI = .1 MPa 5) 1 lb*ft = 1.3558 N*m

SECTION 3.0 SECTION 4.0 – RSL TERMS &

WRENCH DESCRIPTION BOLTING CALCULATIONS
1. AF – Across Flat
1. RSL square drive and hex tools are offered in 2. Full torque hex wrench – A hex wrench with a
seven standard models: 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.
TABLE 3.0-1 3. 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
MAXIMUM OUTPUT TORQUE
MODEL Table 2.1-1.
(LB*FT) (N*M) 4. Reduced torque hex wrench - A hex wrench with a
RSL2 1408 1909 housing which “is not” strong enough to be rated at
the maximum torque for a RSL series. See torque
RSL4 3080 4176
rating in Table 2.2-1 and Table 2.2-2.
RSL6 5303 7190 5. RSL - Ratcheting Slim Line
RSL8 7862 10660 6. RSLxxSDS – RSL Square Drive Wrench Set
RSL14 11154 15123 (e.g. RSL30SDS, RSL4SDS)
RSL20 18843 25547 7. RSLxxHxxx – RSL Hex Wrench Set
RSL30 28002 37966 a. RSLxxHxxx – RSL30H602 (RSL30 for a 6-
Note: See Sections 2.0 & 2.2 for more details. 2/16” or 6-1/8” AF Fastener)
b. RSLxxHxxM – RSL2H60M (RSL2 for a 60 mm
2. See Section 4.0 for definitions of key terms. AF Fastener)
3. RSL torque wrenches (tools): 7. Torque – The tendency of a force to rotate an
a. Enable user to accomplish bolting tasks with object about an axis (twist). Force times distance
high torque, accuracy, and efficiency. from object axis.
b. Are powered by hydraulic pump operated at 8. Torque vs. Pressure Certificate of Precision –A
pressures: torque vs. pressure table and curve for a given
i. Up to 10000 psi (690 bar) for advance power head & wrench assembly.
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: Pump (Console)
- 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). Swivel
Caution!
1. Do not modify any equipment or
accessories.
2. Contact HYDRATIGHT for special
applications or modifications.
3. Unauthorized modifications may
cause injury and/or damage plus
invalidate warranty.
Swivels – Square Drive Wrench
FIGURE 4.0–1 TERMS

SECTION 4.0 (continued)
Low Pressure
Retract Stroke
High Pressure
Advance Stroke
Hex Wrench Head

Power Head (RSLxxHxxxxxx)
Low Pressure
Retract Stroke
High Pressure
Advance Stroke
QD’s for Power Head Hoses Hex Wrench Set

CEJN
Square Drive
Hex Bit
QD’s for Power Head Hoses
(Male Hex Insert)
Screw Type w/ Relief Valve
Square Drive Wrench Head

Reaction Arm
(RSLxxS)
Insert, Hex
Square Drive Wrench Set (SDS)
FIGURE 4.0–2 TERMS FIGURE 4.0–3 TERMS

c. Torque required for stud tension will vary
SECTION 4.0 - TERMS & BOLTING significantly with changes in lubrication friction
CALCULATIONS (CONTINUED) coefficient. Changes may be from contamination,
using different lubrication, etc.
Warning:
- The formula’s below include simplifications
d. Minimize variation in torque required for a given
& give estimates of torque, elongation, etc.
stud tension:
- Use formulas with care for critical applications.
i. Use lubricant with known friction coefficient.
- Refer to ASME PCC-1-2010 for more ii. Periodically calibrate pump/gauge, &
information.
regulate pump pressure.
9. TENSION iii. Perform regular torque vs. pressure
a. To prevent bolted joint leaks, it is necessary to: certificate of precision tests
i. Generate evenly distributed clamp force
11. ELONGATION TENSIONING & CALCULATIONS
around joint.
a. Determine required stud or bolt elongation for
ii. Generate clamp force greater than
desired tension with:
operational loads.
iii. Keep stud tension stress (from clamp force
 Lbe Lte 
and operational loads) below stud material D  F*  
yield strength.  E * As E * Ar 
b. Notes:
i. Create joint clamp force by generating stud b. Where ( Refer to Fig. 4.04-4 & 4.04-5):
tensile load with: D = Stud (bolt) elongation (inch (in.)).
1) Controlled torque applied to nuts Lbe = Body effective length (in.).
2) Controlled stud elongation Lte = Thread effective length (in.).
ii. Correct tension is established by equipment Bolt: Lbe = Lb + h*Lh
manufacturer, and/or governing
Lte = Lt + g*Ln
codes/standards for a particular application.
iii. Tension can be expressed as: Stud: Lbe = Lb
1) Stud tensile stress Lte = Lt1 + g*Ln1 + Lt2 + g*Ln2
2) Percent stud material yield strength Where:
3) Stud elongation Lb = Body length
4) Nut rotation (degrees). h = Head Length Factor (.3 to .6 (.5 typ.))
10. TORQUE TENSIONING & CALCULATIONS Lh = Bolt Head Height
a. Frictional torque between stud/nut threads and Lt, Lt1, Lt2 = Thread length
mating surfaces (e.g. nut face/flange) must be g = Nut Length Factor (.3 to .6 (.5 typ.))
known and controlled to determine torque amount
Ln, Ln1, Ln2 = Nut Thickness
for desired stud (bolt) tension.
b. Determine required torque for desired stud (bolt) E = Stud (bolt) modulus of elasticity (lb/in^2).
tension with: (e.g. Typical Steel = 30000000 lb/in^2 (psi))
As = Stud (bolt) tensile area (in^2)
F  P Rt * ft 
T  *    Rn * fn  Ar = Thread root area (in^2)
12  6.283 cos(  / 2 )  Where:
Where: -----------------------------------------------------------------
T = Torque required (lb*ft).  .9743 
As  .7854 * Db  ^2
F = Tension (Stud/bolt) required (lb).
 n 
P = Thread Pitch (inch/thread)
Formula is for fasteners with yield stress equal to
Rt = Thread pitch radius. (in.) (Fig 4.0-4).
or less than 100000 psi
----------------------------------------------------------------
 D min .16238 
As  3.14159 *   ^2
n 
Dt = Thread pitch dia. (in.) (Fig 4.0-4).
β = Included thread angle (degrees) (Fig 4.0-4).  2
For UN or ISO threads β is typically 60°. Formula is for fasteners with yield stress greater
For β = 60°; cos (60°/2) = .866 than 100000 psi
Rn = Mean nut face radius. (in.) (Fig 4.0-2). ----------------------------------------------------------------
 1.3 
Ar  .7854 * Db  ^2
ƒt = Friction coefficient – threads.  n 
ƒn = Friction coefficient – nut face. ----------------------------------------------------------------
Db = Nominal stud (bolt) diameter (in.).
Dmin = Minimum pitch diameter (in.)
n = Threads per inch

SECTION 4.0 - TERMS & BOLTING SECTION 5.0 - PLANNING

CALCULATIONS (CONTINUED) 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:
FIGURE 4.0-4 i. Use our best customs and practices.
STUD AND NUT DIMENSIONS 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.
FIGURE 4.0-5
BOLT AND NUT DIMENSIONS 3. Hydratight recommends hiring properly trained,
qualified, and certified Joint Assembly Technicians.
c. Determine stud (bolt) elongation by:
i. Measure length before tension = L1 4. Warning! Sections 5.0-1 thru 5.0-3 are extremely
ii. Measure length after tension = L2 important and must be included in planning bolted
iii. Elongation = L2 – L1 joint assembly process. If you require assistance,
iv. If elongating by heat: contact Hydratight.
1) Measure length = L3
2) Apply load by: 5. Tool application:
a) Heat stud (bolt) a. Controlled torque tightening.
b) Turning nut against flange b. Stud elongation tightening.
c) Allow to cool (normally 24 hours) c. Loosen fasteners.
3) Measure length = L4
4) Elongation = L4 – L3 6. Determine required torque:
v. Measure blind hole elongation: a. The best method is to use equipment
1) Drill flat-bottom hole along stud axis. manufacturer’s torque values and follow their
2) Measure hole depth before tension = L5 procedures.
3) Measure depth after tension = L6 b. Table 10.0-1 & 10.0-2 list torque values for
4) Elongation = L6 – L5 common ASTM A193 studs, lubricants, and
d. Calculate torque required to produce a given other conditions.
elongation: c. Warning! Your application must match table
conditions. If application does not match, go to
i. Calculate force (FF) required for given next step.
elongation (DD) using: d. Use Hydratight’s BoltUp® website:
http://www.boltup.com/
 Lbe Lte 
FF  DD /  
 E * As E * Ar 
ii. Calculate torque (TT) to produce force (FF)
using:
FF  P Rt * f 
TT  *    Rn * f 
12  6.283 cos(  / 2 ) 

SECTION 5.0 Warning! To avoid injury or tool damage

PLANNING (cont.) do not exceed maximum torque rating.
ii. Hex wrench tools are used when:
e. Contact Hydratight’s Customer Service. They 1) Limited overhead space & tool with
will determine proper torque free of charge. impact socket will not fit.
Please have this information when you call 2) Lightest weight tool is required.
(Fig. 4.0-4 & Fig. 4.0-5): 3) There are limited numbers of nut sizes.
i. Lubricant type and friction coefficient. 4) Easy bolt-to-bolt change-over is
ii. One of the following. Desired stud (bolt): required.
1) Tensile stress (pounds per sq. in.) 5) Tight bolt patterns require small nose
2) % of material’s yield or tensile strength. radius.
3) Tensile load (pounds force). 6) Minimal tool deflection is required.
iii. Grip length (Lg) c. Different AF hex inserts are available for a given
iv. Stud (bolt): hex wrench model & housing size.
a. Stud (bolt) nominal diameter (Db) 8. Plan tool reaction. Sect. 6.2 (Hex) and 6.3 (Sq. Dr.).
b. Lengths (L, Lb, Lc, Lg, Lh, Ls)
c. Threads per in. (n), or in. per thread (P) 9. Select tool:
d. Grade (B7, B8, B16 etc.). a. Hydratight offers full torque and limited torque
e. Hollow stud’s inner diameter. wrench heads. Reduced torque rating is
v. Nut: marked on wrench housing.
a. Size across flat (AF) b. Table 2.0-1, 2.1-1, 2.2-1, & 2.2-2 list ratings.
b. Thickness (Ln, Ln1, Ln2) c. “Best Practice” method for selecting tool is to
c. Type (regular hex, heavy hex, or other). size tool to operate from 3000 to 6000 psi. for a
d. Grade given tightening torque (3000 to 5000 psi for high
vi. If stud elongation or nut rotation method is usage applications)
used to measure tension, provide: i. This general recommendation offers best
1) Required elongation compromise for tool life, size, maintenance,
2) Required nut rotation & operating cost.
3) Thread length (Lt, Lt1, Lt2) ii. Use Table 2.3-1 to select tool & determine
4) Effective length info. (Section 4.0-11). nominal operating pressure.
vii. Gasket material, type, size, etc.
f. Hydratight recommends sizing a tool for 10. Select hydraulic pump.
loosening (breakout) which is: a. Pump’s tool extend pressure must not exceed
i. At least 1-1/2 to 2 times tightening torque. 10,000 psi (690 bar).
ii. Four times tightening torque for some b. Pump’s tool retract pressure must be between
applications 1500 to 1700 psi (103.4 to 117.2 bar)
c. If electric power cord is long, select proper cord
7. Evaluate which tool should be used (square drive or size to minimize voltage drop.
hex). See figure 5.0-1 and 5.0-2. d. If hoses are long, contact Hydratight to check
a. Sq. dr. tool with impact socket or male hex bit: pressure drop.
i. See Table 2.0-1 for standard square drive
sizes and maximum output torque limits. 11. Check Oil:
ii. RSL square drive tools are used with 3/4" to a. Proper oil (Standard is Hydratight HF-101):
2-1/2" square drive impact sockets. i. Temperature requirement
iii. Square drive tools & impact sockets (or ii. Food grade
male hex bits - Table 2.1-1) are used when: b. Fill console reservoir
1) Little space limitations exist. c. Pre-fill tool
2) Light weight tool required to reduce d. Pre-fill hoses
technician fatigue. e. Eliminate air from oil lines
3) Large quantity of fasteners tightened. 12. Check tool:
4) Maximum tool versatility required. For a. Service properly
a given torque range technician can i. Properly cleaned
easily change sockets for different ii. Properly lubricated
fastener sizes. iii. Inspect all components for cracks/wear and
5) Socket head cap screws (which require repair as needed
male hex drives) are tightened. iv. Eliminate all oil leaks immediately
b. Ensure torque vs. pressure certificate of
b. Hex tool: precision is current. Perform test more
i. Table 2.2-1 and Table 2.2-2 list available full frequently when tool:
& limited-torque hex wrench heads. i. Is used in critical applications.
1) Maximum (max.) operating pressures ii. Is operated in high torque/pressure range.
vary for limited torque hex wrenches. iii. Has been used frequently.
2) Max. torque stamped on wrench. iv. Operates in a dirty environment with
3) Wrench head is rated for max. torque abrasives such as sand.
when torque rating is not on wrench.

SECTION 6.1.0
SECTION 5.0 - PLANNING (cont.) CHOOSE FLANGE ASSEMBLY METHOD
1. TIGHTEN METHOD 1 – Follow equipment
manufacturer procedures
2. TIGHTEN METHOD 2 – Torque, Legacy Cross-
Pattern 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
FIG. 5.0-1 - Square Drive Tool (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.
3. TIGHTEN METHOD 3 – Stud Elongation Tightening

FIGURE 5.0-2 - Hex Tool a. Determine torque value for proper elongation.
i. Section 5.0- 6 & 4.0-11.
ii. (or) Contact Hydratight Customer Service
SECTION 6.0 b. Follow steps in TIGHTEN METHOD 2
OPERATING INSTRUCTIONS - FLANGE c. After 4th stage, if studs are:
i. Short – increase torque & tighten until studs
ASSEMBLY & DISASSEMBLY are proper length.
ii. Long – loosen until studs are proper length.
1. Perform hazard analysis before starting work d. Caution: Do not over-stretch studs because
2. If critical application, see Section 5.0 (1. thru 4.) joint parts may fail.
3. Ensure fastener contact surfaces & flanges have 4. TIGHTEN METHOD 4 – Use Guidelines for Pressure
been properly cleaned and examined Boundary Bolted Flange Joint Assembly (ASME
a. Flanges PCC-1-2010).
i. Surface finish, Scratches, Nicks, Burrs,
Flatness
ii. Nut bearing surface – No paint or other thick SECTION 6.1.1
coating, Not scored FLANGE DISASSEMBLY (LOOSEN)
b. Fasteners:
i. No rust, corrosion, burrs 1. Use following when corrosion is present to minimize
ii. Make sure bolt/nut will turn freely by hand required torque to allow lower pump pressure &
beyond position where it will come to rest. increase pump & tool life:
Do not lubricate for this test. a. Apply SWEENEY 501 penetrating oil to nuts &
iii. Fastener replacement is always safe option wait for 5 minutes (minimum).
iv. See ASME PCC-1-2010 for fastener b. Heat fastener for hard applications with severe
replacement guidelines corrosion, high torque requirements, etc.:
4. Ensure: i. Consult with equipment manufacture
a. Joint members are properly aligned ii. Take necessary safety precautions for high
b. Gasket is properly installed temperatures (Flammable materials, proper
c. Lubrication of fastener working surfaces been protective equipment, etc.).
properly considered iii. Be safe, allow parts to cool.

SECTION 6.1.1 (cont.) Figure 6.1.2-1 Notes:

2. Loosen all nuts 1/8 turn. To increase tool and pump o When bolt numbering is correct:
life set lowest pressure which consistently works.  All bolts on right side of flange will be odd numbers
a. Cameron BOP Bonnet – loosen bolts in four (e.g. “1”, “5”, “3”, & “7”).
post pattern  Bolts on left will be even numbers.
b. Other – loosen bolts sequentially from nut to nut o For more application based procedures refer to:
 Guidelines for Pressure Boundary Bolted Flange
3. If torque required to initially loosen nuts was: Joint Assembly (ASME PCC-1-2010)
a. Less than 150% of tightening torque, then  Hydratight Sweeny Joint Integrity Assurance
remaining tension may be fully removed from procedures.
each stud sequentially.
b. Greater than 150% tightening torque, repeat 2. SECTION 6.2
c. Warning! Stud or flange damage may occur
when all tension is removed from first stud
HEX TOOL REACTION
without loosening others. Damage occurs
because loosened stud’s load is transferred to 1. Hex insert must be correct size across flat (AF)
remaining studs. 2. Hex nut must have full nut thickness covered by hex insert
3. Hex wrench must be square to stud center line
SECTION 6.1.2 4. Reaction surface must be parallel to reaction arm surface
5. Determine if thread is right hand (RH) or left hand (LH)
FLANGE ASSEMBLY EXAMPLE – METHOD 2 6. Determine if fastener will be loosened or tightened
Examples: Legacy Cross-Pattern Tightening a. Plan to place hex wrench head on nut for loosening.
Sequence b. Plan to place hex wrench head on nut for tightening
(See fig. 6.2-1 for RH thread).
4 Bolt Flange 1-3-2-4 7. Fig. 6.2–1 - Proper hex tool reaction with reaction arm.
a. Preferred reaction method is to use reaction arm.
8 Bolt Flange 1-5-3-7-2-6-4-8
b. Contact Hydratight Customer Service or Engineering
12 Bolt Flange 1-5-9-3-7-11-2-6-10-4-8-12 for special reaction arms, or spline covers.
c. Do not react at sharp angle on reaction arm.
16 Bolt Flange 1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16 i. Arrows in fig. 6.2-2 (upper left) show this.
20 Bolt Flange 1-13-5-17-9-3-15-7-19-11-2-14-6-18-10-4- ii. May cause damage to spline and/or reaction arm.
16-8-20-12 iii. Contact Customer Service for these applications.
28 Bolt Flange 1-13-21-5-17-9-25-3-15-23-7-19-11-27-2- 8. Figure 6.2-5 (top) shows a common reaction method. RSL
14-22-6-18-10-26-4-16-24-8-20-12-28 reacts on power head housing’s flat surface.
32 Bolt Flange 1-17-9-25-5-21-13-25-3-19-11-31-7-29-15- Warning! Do not react against power head splines
27-2-18-10-30-6-22-14-26-4-20-12-32-8-24- (Fig. 6.2-5 (bottom)). Use spline cover (RSLxx-700S)
16-28 to prevent damage.
9. “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.
st nd rd
(a) Marked up (b) 1 , 2 , and 3 Stage
8 Bolt Flange Cross-Pattern Sequence
(c) 4th & Final Stage -

Adjacent Bolt to Bolt
Sequence
FIGURE 6.2-1
FIGURE 6.1.2-1 PROPER REACTION FOR HEX TOOL WITH
LEGACY CROSS-PATTERN TIGHTENING REACTION ARM
SEQUENCE FOR 8 BOLT CIRCULAR FLANGE (Reaction arm must be as shown)


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
1. Determine if fastener is right hand or left hand thread
2. Determine if fastener will be loosened or tightened
FIGURE 6.2-3 a. Plan to place square drive (sq. dr.) wrench head on
PROPER HEX TOOL REACTION WITH nut for loosening (See figure 6.3-1 & 6.3-2).
b. Plan to place square drive (sq. dr.) wrench head on
REACTION “BUMP” nut for tightening (See figure 6.3-1 & 6.3-2).
3. Fig. 6.3-1 & 6.3-2 show proper sq. dr. tool reaction. Arrow
by hose points to gap required for proper reaction.
4. 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
FIGURE 6.2-4 d. Lifting (cocking) is when a socket fits over bolt at an
IMPROPER HEX TOOL REACTION angle. It:
DO NOT REACT ON HEX WRENCH HOUSING i. Is a common cause of socket breakage
(NO REACTION BUMP) 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


5. 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, DO NOT REACT SQ. DR. TOOL WITH ARM IN
rotate arm in direction of sq. dr. until gap appears. Do DIRECTION SHOWN – SOCKET MAY FRACTURE
not rotate more than 3 degrees. Angle in Fig. 6.3-1
Requires a Gap
(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.
6. Contact Hydratight Customer Service or Engineering for

special reaction arms for non-standard applications.
Note: Arrow(s) point to required gap. FIGURE 6.3-3

IMPROPER SQ. DR. TOOL REACTION
FIGURE 6.3–1 - PROPER REACTION 7. Square Drive Reaction Arm Extensions - Reaction arms
(RH THREADS - SQUARE DRIVE TOOL) 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
Push Here 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:
LOOSENING 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.
TIGHTENING
ii. Use Flux Core E71T-1 weld rod (or equivalent).
Warning!
i. Follow these instructions so maximum allowable
FIGURE 6.3–2 - PROPER REACTION torque is not reduced.
(RH THREADS – SQ. DR. TOOL) 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.


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 TABLE 6.4-1
1. Hydratight inspects all tools prior to shipment. However:
a. Inspect for tool damage, leaks, etc. before each use. Power Head Bolt Torque
b. Verify that all parts are included.
c. Do not use hoses as a handle or lift strap when Long Bolts Short Bolts
lifting or moving tool.
MODEL
2. Select proper tool and accessories (See section 5.0): Lb*ft N*m Lb*ft N*m
a. Torque rating
RSL2 19 26 23 31
b. RSLxxSDS - Square drive wrench & power head
i. Reaction arm, or other. RSL4 35 48 45 61
ii. Square drive AF (across flat) RSL6 60 82 105 142
iii. Male hex bit. Table 2.1-1 (for socket head cap RSL6A 85 116 105 142
screws) RSL8 170 231 210 285
iv. Socket (for hex head cap screws & nuts):
RSL14 110 149 110 149
1) Fastener AF
2) Short or long RSL20 90 122 90 122
c. RSLxxHxxx – Hex wrench and power head RSL30 150 203 150 203
i. Reaction arm, tube, sleeve, or other Notes:
ii. Proper hex insert 1. Use lubricant (oil)
3. (Hex Wrench) Change hex wrench insert for proper AF. 2. Similar bolts have different torque values
because required clamp loads vary


g. Threaded QD assembly procedure (fig. 6.4-3)
5. (As needed – sq. dr.) Change sq. dr. assembly i. Pull female threaded collar back
direction from tighten to loosen (or vice-versa): ii. Insert male section into female section.
a. Remove square drive retainer iii. Screw female collar onto male section until
i. Pull on end of retainer to release ball detents collar solidly contacts male shoulder.
ii. Remove square drive retainer assembly
b. Remove and reposition square drive Female QD
c. Assemble drive retainer Low Pressure Retract
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 Relief Valve
detents
Male QD
6. (As needed – sq. dr.) Assemble socket to sq. dr. & High Pressure Advance
secure socket to square drive with o-ring & pin.
7. (As needed) Assemble reaction arm ass’y. to wrench. FIG. 6.4-3 - QD’s - THREADED TYPE
a. Rotate dialock to allow reaction arm to slide on to
power head splines. 10. Purge all air from tool before returning to service.
b. Slip reaction arm over power head splines until it Suggested method:
stops against o-ring. a. Connect Power Head to pump.
c. Rotate dialock (any direction) to next “click” (60 b. Place Power Head below pump
degrees), to lock reaction arm in place. c. Extend piston to end of stroke.
d. Check dialock engagement - pull reaction arm. d. Remove hoses from power head & connect
e. Warning! Dialock must be in locked position hoses together.
before using tool! e. Turn pump on and run for one minute.
f. (As needed) Secure reaction arm ass’y. to power f. Repeat until rod extends & retracts smoothly.
head with safety cable. Sect. 1.0 – RSL Safety. 11. Tighten or loosen fasteners in accordance with
instructions in Section 6.1.
8. Connect air or electrical power source to hydraulic a. TIGHTEN METHOD 1 - Follow equipment
pump. See pump manual. manufactures procedures.
b. TIGHTEN METHOD 2 - Torque - Legacy Cross-
9. Assemble twin hose to pump (1st) & tool (2nd) before Pattern Tightening Sequence & Bolt Numbering
setting tool on application. Fig. 6.4-(2/3/4) & 8.1-1. System – One Tool
a. Each end of a twin hose will have one male and c. TIGHTEN METHOD 3 – Stud Elongation
one female quick connect fitting (QD). d. TIGHTEN METHOD 4 – See Guidelines in
b. Pump will have like male/female fittings. Pressure Boundary Bolted Flange Joint Ass’y.
c. Connect pump high pressure advance stroke e. LOOSEN (BREAKOUT)
port to tool high pressure advance port. f. Note: Power Head, Square Drive Wrench Head,
d. Connect remaining low pressure ports. Socket & Reaction Arm can be moved as a unit.
e. Always use an odd number (1, 3, 5 …) of twin g. Note: Remember fasteners are typically
hose assemblies to connect tool to pump. tightened, or loosened, incrementally. e.g. All
f. CEJN QD assembly procedure (fig. 6.4-2): fasteners are loosened 1/8 turn in a first pass.
i. Unscrew locking collar on female QD. 12. Determine if fastener will be loosened or tightened.
ii. Slide outside slide ring back. Snap male and Set-up tool on proper nut according to the following:
female fittings together. a. Tighten right hand threads: Place tool on nut so
iii. Release slide ring. tool advance stroke will rotate nut clockwise.
iv. Screw locking collar back against slide ring. b. Loosen right hand threads: Place tool on nut so
tool advance stroke will rotate nut counter-
clockwise.
c. (As needed) Change square drive position to
Locking Collar loosen or tighten. See Section 6.4 – 5.
13. Reaction and tool leak check:
Slide Ring a. Check that reaction arm is in firm contact with
Female QD stationary object (e.g. nut, flange, or housing).
Low Pressure Retract 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
Male QD 1) If tool reacts improperly (e.g. Lifts over
High Pressure Advance reaction point), re-do reaction setup
2) If tool leaks, repair leaks immediately
c. Set pressure to minimum required for
FIGURE 6.4 - 2 application to maximize tool life.
HOSE QD’s – CEJN TYPE

3. Before each use:
SECTION 6.4 (continued) a. Inspect tool structure (including splines, power head,
14. To tighten a single fastener: reaction arm, etc.) for cracks, chips, galling, or
a. Pressure adjustment: deformities. If irregularities are found, service or
i. Best practice is to use minimum tool replace immediately.
pressure to extend tool life. Do not operate b. Check retractor, bronze block, & retractor pin for fit.
tool at max. if a lower pressure will work. c. Clean hoses & hose quick couplers.
ii. For new applications set pump pressure d. Confirm power head & wrench head are:
near zero to start i. Properly engaged – Retractor pin is inserted
iii. Gradually increase pressure and carefully properly in pawl driver slot
watch tool for proper reaction and oil leaks ii. Secured properly with socket head cap screws.
iv. If tool does not react properly (e.g. Lifts Torque screws per Table 6.4-1.
over reaction point), re-do reaction setup
b. Depress & hold pendant control button until 7.3 POWER HEAD ASSEMBLY, TESTING, &
power head makes complete advance stroke. DISASSEMBLY.
c. Release control button to retract power head NOTES:
d. During process operator must ensure reaction  Order all replacement fasteners from Hydratight
arm is in constant contact with reaction point.  Use Hydratight HF-101 hydraulic oil
i. Follow all safety rules during this process  Assembly notes for all power heads:
(Pinch points, high pressure hydraulic, …) o Before assembly:
ii. This prevents creation of a pinch point  Clean all components
between tool & reaction point  Lubricate all surfaces with oil (especially seals).
e. Continue process until tool stalls (Pawl does not  Replace seals & wear rings as needed.
engage with another tooth on square driver). o Torque Zero Leak Plug to 80 ±4 lb*in (9 ±.5 N*m)
f. Release pendant control button to retract power  RSL2B, RSL4B, RSL6A, RSL8A, and RSL14B
head. Depress & hold control button one more  Item 21, part number 936633 in Table 9.0-1
time to attempt to turn nut. o Purge air from tool. See section 6.4 – 10.
g. If nut does not turn, desired torque is achieved o Spanner Wrench – See Section 11.0 – 15
with related stud tension.
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.
Low Pressure Retract c. Remove pin joining Retractor with Piston (or 10-24 x
1.5 socket head cap screw on RSL8).
High Pressure Advance 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,
FIGURE 6.4-4 RSL14B & RSL20 - With Front Cap
POWER HEAD PORTS a. Install seals & wear band into front cap & piston as
needed
SECTION 7.0 - WARRANTY, b. Slide front cap on rod until it contacts piston.
c. Press piston into power head bore until front cap
MAINTENANCE & ASSEMBLY contacts internal threads. Do not press on spherical
7.1 WARRANTY – These items void tool warranty: radius surfaces.
d. Use spanner wrench to tighten front cap until firmly
1. Failure to use Hydratight replacement parts seated (RSL4A and B models to 60 lb-ft).
2. Inadequate or improper lubrication e. Reinstall retractor, bronze block, and retractor pin
3. Failure to replace worn or cracked parts (RSL8 has a socket head cap screw which is
4. Operating tool at excessive pressure tightened to 40 lb*in, & use blue loctite).
5. Striking our tool with a hammer or other impact device
6. Tool modification 3. Test Power Head Assembly – All Models
7. Improper reaction method a. Follow all applicable safety rules in Section 1.
8. See our tool warranty for complete details. b. Connect power head to console with hoses.
c. Place power head in protective container.
7.2 POWER HEAD MAINTENANCE d. Advance & retract piston three times.
e. Make sure piston moves freely.
1. If seal has small leak, replace seal because of high f. Advance piston and hold at 10,000 psi for 5 seconds.
hydraulic pressure hazard. See Table 9.0-5 for seal kits. g. Repeat 3. f. two more times.
2. Clean & lubricate bronze block & pawl driver mating h. Follow proper lockout & tag policy for console & tool
surfaces. Use Sweeney 503 Moly Paste. Frequency: i. Check power head, hoses, fittings, etc. for leaks.
a. Depends on work environment - increase frequency if i. No leaks: Disconnect hoses.
tool is exposed to sand or other abrasive material ii. Leaks:
b. Frequently with high operating pressure 1) Fix leaks
c. Increased frequency lengthens tool life 2) Repeat test. Start at 3.a.

5. Wrench Assembly:
SECTION 7.3 (continued) a. Before assembly:
i. Replace worn, cracked, damaged, etc. parts
4. Disassemble – Model RSL30
ii. Clean all components
a. Position power head at mid stroke iii. Lubricate all moving surfaces with SWEENEY
b. Install mating QD’s to QD on power head.
503 Moly Paste.
c. Remove pin joining retractor with piston
iv. Inspect pawl teeth engagement (fig. 7.3-2): It
d. Remove end cap bolts
is extremely important that pawl & square
e. Remove end cap driver (or hex insert) teeth are in precise
f. Pour out hydraulic oil.
engagement.
g. Remove piston by pressing on its end. (Do not press
b. Reverse wrench disassembly steps
on spherical radius surfaces).
5. Assemble – Model RSL30
a. Install seals & wear rings into end cap, front cap, & STORAGE:
piston as needed - Clean & lubricate tool if stored (not used) for 5 days or more.
b. Insert piston into cylinder to end of stroke.
c. Fill to high pressure inlet hole with hydraulic oil. SERVICE:
d. Assemble end cap to power head. - Hydratight highly recommends customers have their tools
i. Tighten 22 bolts to 22 lb*ft. repaired by Hydratight or a Hydratight approved service
ii. Lubricate bolts with hydraulic oil. 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, Inspect For
deformities, and wear. Cracks
a. Immediately replace parts which have cracks, chips,
deformities, or excessive wear FIGURE 7.3-1
b. Inspect: Square drive, square driver, pawl (fig. 7.3-1),
pawl driver, pawl holding spring(s), sq. dr. wrench PAWL INSPECTION
housing, hex wrench housing halves, fasteners, etc.
Pawl Teeth Must be in
3. Hex wrench disassembly: Precise Engagement
a. Remove socket head cap screw joining hex wrench with Square Driver or
housings. Hex Insert Teeth
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.
FIGURE 7.3-2
PAWL TEETH ENGAGEMENT

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 1. Quick connect couplings are: 1. Clean & properly connect
retract. a. Improperly assembled. couplings. Use pliers to tighten
- Pump gauge shows hydraulic b. Worn & not properly engaged. screw-on type.
pressure. 2. Piston seal is worn & hydraulic 2. Replace worn couplings.
- Pump is running. fluid is leaking past piston. 3. Change piston seal.
1. Add proper hydraulic fluid. See

Power head rod does not fully extend 1. Low console fluid level.
pump manual.
when tool is not mounted on a stud. 2. Air in hoses.
2. Remove air. Section 6.4-10.
1. See pump manual.

2. If possible, install valve upgrade.
1. Air valve sticks due to: 3. Air valve:
- Power head rod will not extend at all. a. Moisture, or dirt in air supply. a. Clean air valve.
- Pump gauge reads zero. b. Valve corrosion. b. Service air line filter
- Pump is running.
2. Solenoid valve sticks. 4. Solenoid valve:
a. Clean solenoid valve.
b. Check line voltage.
Tool operates backwards. Advance Quick couplings are reversed on

Properly install quick couplings.
stroke button retracts piston rod. hoses, pump, or power head.
Tool does not operate even though 1. Improper power head & wrench
1. Assemble correctly.
pump is running & all connections are assembly.
2. Replace retractor pin.
properly connected. 2. Retractor pin is sheared.
- Disassemble wrench.
- Clean & inspect
Wrench operation sluggish &/or noisy. Poor lubrication.
- Replace broken parts as needed
- Lubricate all moving surfaces.
Nut partially returns with socket when Torsion on stud is causing nut to
Properly lubricate stud & nut threads.
power head retracts. return with stud.
Nut rotates with socket for power head - Nut too loose & thread friction will
Tighten nut sufficiently before using
extension & returns to starting position not overcome pawl spring.
tool
on retraction - Tool loses “ratchet” capability.
1. Tool is not level or perpendicular 1. Reposition tool &/or reaction arm so
to stud centerline (“out of square” it is level & perpendicular to stud
Nut does not rotate as many degrees
engagement). centerline (perform “floor test”).
as wrench (or socket).
2. Nut corners are rounded off. 2. Replace nut.
3. Socket or hex insert is over-size 3. Use smaller socket or hex insert.

SECTION 8.1
GENERAL HYDRAULIC TROUBLE SHOOTING
FIGURE 8.1-1
GENERAL HYDRAULIC TROUBLE SHOOTING
SECTION 9.0
Part Numbers & Drawings
Fig 9.0-1
RSL POWER HEAD
Notes:
1) To order replacement parts specify: Tool Style, Model Number, Serial Number, Description, and Part Number (see part lists).
2) Order all replacement parts from Hydratight (see website).
3) For other tool models refer to original manual or contact Hydratight.
4) 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.
5) 503 moly paste lubricant is part number 100002813 for a 4 lb can

TABLE 9.0-1
RSL POWER HEAD PART LISTS
POWER HEAD MODELS AND PART NUMBERS
ITEM DESCRIPTION QTY
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 Front Cap 1 RSL2-3 RSL4-3B RSL6-3 RSL8-3 RSL14-3A RSL20-3 N/A
6 O-Ring (Front Cap) 1 A000282070001 A000282076006 A000282080001 A000282086001 A000282090001 A000282098001 N/A
7 Gland Seal 1 942272 942361 942364 942359 942367 942358 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 Pin, (Inner) 1 N/A N/A A000141185001 A000141185001 A000141165001 A000141185001 A000141185001
11 Block, Bronze 1 RSL2-4A RSL4-4 RSL6-4 RSL8-4 RSL14-4 RSL20-4 RSL30-4
12 Pin, Roll 1 A000141192001 A000141194001 A000141198001 N/A A000141201001 A000141203001 A000141203001
Pin, Roll (or screw) 1 A000141221001
13 N/A A000141194001 RSL6-55 A000151769001 A000141203001 A000141183001
RSL14 - Pin in pin 2 & A000141169001
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 Hose, Black - X1-192 (qty 2) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1) X1-422BLK (qty 1)
17 Hose, Blue - - X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1) X1-422BLU (qty 1)
18 QD, Male 1 936541 936541 936541 936541 936541 936541 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
21 Plug 1 936633 936633 936633 936633 936633 A000371564001 Not Available
22 Sign, Safety 2 RSL-308 RSL-308 RSL-308 RSL-308 RSL-308 RSL-308 RSL-308
Reaction Arm
23 1 RSL2-70A RSL4-70A RSL6-70 RSL8-70A RSL14-70A RSL20-70 RSL30-710
Assembly
24 (a) Overlay, Console 1 X1-18 X1-1 X1-15 X1-14 X1-5 X1-16 X1-6
25 (a) Model Plate 1 N/A N/A RSL6-100A RSL8-100 N/A N/A RSL30-100
Hex Key - for short
27 (a) 1 913007 (1/4) 913009 (5/16) 913012 (3/8) 913023 (1/2) 913021 (5/8) 913021 (5/8) 913022 (3/4)
screw
Hex Key – for long
28 (a) 1 N/A N/A N/A N/A 913020 (1/2) N/A N/A
screw
29 (a) Hex Key – for hex head 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) 1 N/A N/A N/A N/A N/A N/A RSL30-3
31 (a) End Cap Seal(s) 1 N/A N/A N/A N/A N/A N/A 942334&942335
32 (a) End Cap Bolts 22 N/A N/A N/A N/A N/A N/A A000151829001
33 (a) Gland Wear Ring 1 N/A N/A N/A N/A N/A N/A 942326
Note: (a) - Not shown. (b) - See Section 6.4-1 for bolt torque specifications. (c) – Use Hydratight HF-101 Oil at Assembly

FIGURE 9.0-2 - RSL HEX WRENCH HEAD PARTS

TABLE 9.0-2
HEX WRENCH HEAD PART LISTS
HEX WRENCH MODELS AND PART NUMBERS
RSL2H RSL4H RSL6H RSL8H RSL14H RSL20H RSL30H
1 PAWL 1 RSL2HXXX-3 RSL4HXXX-3 RSL6HXXX-3 RSL8HXXX-3 RSL14HXXX-3 RSL20HXXX-3 RSL30HXXX-3
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
6 (a) 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
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.

FIGURE 9.0-3 Hex Bit (option)

RSL Square Drive Wrench Head Parts (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 PAWL 1 RSL2S-3 RSL4S-3 RSL6S-3 RSL8S-3 RSL14S-3 RSL20S-3 RSL30S-3
2 SPRING 1 (2) 950291 950302 950250 950250 (2) 950255 950263 950263 (2)
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

RSL20-70
(Stainless
Steel)
RSL2 THRU RSL14 RSL30-710

(Stainless Steel) (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
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

SECTION 9.0 - Part Numbers and Drawings

Seal Kits - Parts Lists and Seal Placement Guide
Notes:
1. Seal replacement requires proper procedures to disassemble & assemble power head. See Section 7.0.
2. Use table and drawing below as a seal placement guide.
3. RSLxx-SKX - Universal Seal Kit consists of all seals for each respective RSL model (Not Available (N.A.) for RSL14).
4. RSL4-SKV - Viton seals for special environment driven applications.
TABLE 9.0-5
POWER HEAD SEAL KITS
Item Number 1 2 3 4 5 6 7
End End
Piston Rod Cap Cap
Piston
Seal Kit RSL Model Wear Rod Seal Wear Front Cap Seal Seal Seal
Seal
Ring Ring
(groove) (corner)
RSL2-SKRD RSL2 (rev D) A000282015001 n/a n/a n/a
RSL2 n/a n/a n/a
942348 942349 A000282070001
RSL2-SK RSL2A 942272 n/a n/a n/a
RSL2B n/a n/a n/a
RSL4-SK RSL4* A000282019001 942299 942302 n/a
RSL4-SKA RSL4A 942300 942301 n/a A000282026001 n/a n/a
942361
RSL4-SKB RSL4B n/a A000282076006 n/a n/a
RSL4-SKV RSL4A 942370 942301 942371 n/a A000282026004 n/a n/a
RSL6-SKRC RSL6 (rev C) A000282023001 n/a n/a n/a
RSL6-SK RSL6 942355 942354 n/a A000282080001 n/a n/a
942364
RSL6-SKA RSL6A n/a n/a n/a
RSL8-SKRH RSL8 (rev H)** A000282026001 n/a n/a n/a
942346 942347 A000282086001
RSL8-SK RSL8A 942359 n/a n/a n/a
RSL14-SK RSL14 (N.A.) Not Available (N.A.) (N.A.) n/a (N.A.) n/a
RSL14-SKA RSL14A 942304 942306
342367 n/a A000282090001 n/a n/a
RSL14SKB RSL14B
RSL20-SK RSL20 942356 942360 942358 n/a A000282098001 n/a n/a
RSL30-SKRL RSL30 (rev L) A000282084001 n/a
942327 942328 942326 942335 942334
RSL30-SK RSL30 942362 n/a
* 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

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)
TORQUE (T) FOR SPECIFIED LUBRICANT (LB*FT)

BOLT
NOM. THD/IN TENSION
BOLT (UNC/
MINIMUM
LOAD STUD f – FRICTION COEFFICIENT (ft = fn)
YIELD
SIZE UNF) (ROOT ELONGATION DRY
STRENGTH
Db n AREA) 503 504 505 506 507 API MACHINE STEEL
Fr SWEENEY SWEENEY SWEENEY SWEENEY SWEENEY SA2 OIL ON
STEEL
-3
(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 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
1 8 105000 29556 1.750 229 319 349 379 349 409 499 650
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)

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)
TORQUE (T) FOR SPECIFIED LUBRICANT (LB*FT)

BOLT
NOM. THD/IN TENSION
BOLT (UNC/
MINIMUM
LOAD STUD f – FRICTION COEFFICIENT (ft = fn)
YIELD
SIZE UNF) (ROOT ELONGATION DRY
STRENGTH
Db n AREA) 503 504 505 506 507 API MACHINE STEEL
Fr SWEENEY SWEENEY SWEENEY SWEENEY SWEENEY SA2 OIL ON
STEEL
-3
(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)

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
2,000 PSI 3,000 PSI 5,000 PSI 10,000 PSI 15,000 PSI 20,000 PSI
SIZE
DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD
2-1/16 5/8 8 5 7/8 8 6-1/2 7/8 8 6-1/2 3/4 8 6-1/4 7/8 8 6-7/8 1-1/8 8 9-1/16
2-9/16 3/4 18 5-7/8 1 8 7-1/2 1 8 7-1/2 7/8 8 7-1/4 1 8 7-7/8 1-1/4 8 10-5/16
3-1/16 - - - 1 8 9-1/16 1-1/8 8 9-1/16 1-3/8 8 11-5/16 1-1/8 8 9-1/16 1-3/8 8 11-5/16
3-1/8 3/4 8 6-5/8 7/8 8 7-1/2 1-1/8 8 8 - - - - - - - - -
4-1/16 7/8 8 8-1/2 1-1/8 8 9-1/4 1-1/4 8 10-3/16 1-1/8 8 10-3/16 1-3/8 8 14-1/16 1-3/4 8 14-1/16
5-1/8** 1 8 10-1/2 1-1/4 8 11 1-1/2 8 11-1/2 1-1/8 8 11-13/16 - - - - - -
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 - - - - - - 2 20 31-5/8 2-1/4 24 36-7/16 - - - - - -
20-3/4 - - - 2 20 31-5/8 - - - - - - - - - - - -
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

SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-2
AMERICAN NATIONAL STANDARD (ANSI) FLANGE SPECIFICATIONS
FLANGE
150 300 400 600 900 1,500 2,500
SIZE
DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD
2 5/8 4 4-3/4 5/8 8 5 5/8 8 5 5/8 8 5 7/8 8 8-1/2 7/8 8 6-1/2 1 8 6-3/4
3 5/8 4 6 3/4 8 6-5/8 3/4 8 6-5/8 ¾ 8 6-5/8 7/8 8 7-1/2 1-1/8 8 8 1-1/4 8 9
4 5/8 8 7-1/2 3/4 8 7-7/8 7/8 8 7-7/8 7/8 8 8-1/2 1-1/8 8 9-1/4 1-1/4 8 9-1/2 1-1/2 8 10-3/4
5 3/4 8 8-1/2 3/4 8 9-1/4 7/8 8 9-1/4 1 8 10-1/2 1-1/4 8 11 1-1/2 8 11-1/2 1-3/4 8 12-3/4
6 3/4 8 9-1/2 3/4 12 10-5/8 7/8 12 10-5/8 1 12 11-1/2 1-1/8 12 12-1/2 1-3/8 12 12-1/2 2 8 14-1/2
8 3/4 8 11-3/4 7/8 12 13 1 12 13 1-1/8 12 13-3/4 1-3/8 12 15-1/2 1-5/8 12 15-1/2 2 12 17-1/4
10 7/8 12 14-1/4 1 16 15-1/4 1-1/8 16 15-1/4 1-1/4 16 17 1-3/8 16 18-1/2 1-7/8 12 19 2-1/2 12 21-1/4
12 7/8 12 17 1-1/8 16 17-3/4 1-1/4 16 17-3/4 1-1/4 20 19-1/4 1-3/8 20 21 2 16 22-1/2 2-3/4 12 24-3/8
14 1 12 18-3/4 1-1/8 20 20-1/4 1-1/4 20 20-1/4 1-3/8 20 20-3/4 1-1/2 20 22 2-1/4 16 25 - - -
16 1 16 21-1/4 1-1/4 20 22-1/2 1-3/8 20 22-1/2 1-1/2 20 23-3/4 1-5/8 20 24-1/4 2-1/2 16 27-3/4 - - -
18 1-1/8 16 22-3/4 1-1/4 24 24-3/4 1-3/8 24 24-3/4 1-5/8 20 25-3/4 1-7/8 20 27 2-3/4 16 30-1/2 - - -
20 1-1/8 20 25 1-1/4 24 27 1-1/2 24 27 1-5/8 24 28-1/2 2 20 29-1/2 3 16 32-3/4 - - -
24 1-1/4 20 29-1/2 1-1/2 24 32 1-3/4 24 32 1-7/8 24 33 2-1/2 20 35-1/2 3-1/2 16 39 - - -

SECTION 10.1
FLANGE REFERENCE
TABLE 10.1-3
MANUFACTURER’S STANDARDIZATION SOCIETY OF VALVE AND FITTINGS INDUSTRY, INC.
PIPE 150 300 400 600 900

SIZE
DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD DIA NO BCD
12 7/8 12 17 1-1/8 16 17-3/4 1-1/4 16 17-3/4 1-1/4 20 19-1/4 1-3/4 20 21
14 7/8 12 18-3/4 1-1/8 20 20-1/4 1-1/4 20 20-1/4 1-3/8 20 20-3/4 1-1/2 20 22
16 1 16 25-1/4 1-1/4 20 20-1/5 1-3/8 20 22-1/2 1-1/2 20 32-3/4 1-5/8 20 24-1/4
18 1-1/8 16 22-3/4 1-1/4 24 24-3/4 1-3/8 24 24-3/4 1-5/8 20 25-3/4 1-7/8 20 27
20 1-1/8 20 25 1-1/4 24 27 1-1/2 24 27 1-5/8 24 28-1/2 2 20 29-1/2
22 1-1/4 20 27-3/4 1-1/2 24 29-1/4 1-5/8 24 29-1/4 1-3/4 24 30-2/3 - - -
24 1-1/4 20 29-1/2 1-1/2 24 32 1-3/4 24 32 1-7/8 24 33 2-1/2 20 35-1/5
26 1-1/4 24 31-3/4 1-5/8 28 34-1/2 1-3/4 28 34-1/2 1-7/8 28 36 2-3/4 20 37-1/2
28 1-1/4 28 34 1-5/8 28 37 1-7/8 28 37 2 28 38 3 20 40-1/4
30 1-1/4 28 36 1-3/4 28 39-1/4 2 28 39-1/4 2 28 40-1/4 3 20 42-3/4
32 1-1/2 28 38-1/2 1-7/8 28 41-1/2 2 28 41-1/2 2-1/4 28 42-1/2 3-1/4 20 45-1/2
34 1-1/2 32 40-1/2 1-7/8 28 43-1/2 2 28 43-1/2 2-1/4 28 44-1/2 3-1/2 20 48-1/2
36 1-1/2 32 42-3/4 2 32 46 2 32 46 2-1/4 28 47 3-1/2 20 50-3/4
38 1-1/2 32 45-3/4 1-1/2 32 43 1-3/4 32 44 2-1/4 28 45-3/4 3-1/2 20 50-3/4
40 1-1/2 36 47-1/4 1-5/8 32 45-1/2 1-7/8 32 46-1/4 2-1/4 32 47-3/4 3-1/2 24 52-3/4
42 1-1/2 36 49-1/2 1-5/8 32 47-1/2 1-7/8 32 48-1/4 2-1/2 28 50-1/2 3-1/2 24 54-3/4
44 1-1/2 40 51-3/4 1-3/4 32 49-3/4 2 32 50-1/2 2-1/2 32 52-1/2 3-3/4 24 67-2/3
46 1-1/2 40 53-3/4 1-7/8 28 52 2 36 52-3/4 2-1/2 32 54-3/4 4 24 60-1/2
48 1-1/2 44 56 1-7/8 32 54 2-1/4 28 55-1/4 2-3/4 32 57-1/2 4 24 62-1/2
50 1-3/4 44 58-1/4 2 32 56-1/4 2-1/4 32 57-1/2 3 28 60 - - -
52 1-3/4 44 60-1/2 2 32 58-1/4 2-1/4 32 59-1/2 3 32 62 - - -
54 1-3/4 44 62-3/4 2-1/4 28 61 2-1/2 28 62-1/4 3 32 64-1/4 - - -
56 1-3/4 48 65 2-1/4 28 63 2-1/2 32 64-1/4 3-1/4 32 66-3/4 - - -
58 1-3/4 48 67-3/4 2-1/4 32 65 2-1/2 32 66-1/4 3-1/4 32 68-3/4 - - -
60 1-3/4 52 69-1/4 2-1/4 32 67 2-3/4 32 69 3-1/2 28 71-3/4 - - -

SECTION 10.2 SECTION 11.0

STUD & NUT SIZE CROSS REF. TOOL ACCESSORIES & OPTIONS
TABLE 10.2-1 1. SWIVEL – TWO WAY

NUT/BOLT A/F vs. STUD SIZE MODEL PART NUMBER QTY.
a. RSL2 X1-202B 2
NUT / BOLT (A/F) STUD / BOLT NOM. DIA.
b. RSL4 thru 30 X1-200B 2
INCH mm INCH mm
1-1/8 RB 3/4 2. QUICK RELEASE COUPLINGS (QD) – SCREW TYPE
30 20RB 3. QUICK RELEASE COUPLINGS (QD) – CEJN
1-1/4 H 3/4
1-5/16 RB 7/8 4. DUST COVER – SCREW TYPE QD
34 20H
5. REACTION ARM – WELDABLE STEEL
36 24RB, 22H
1-7/16 H 7/8 6. REACTION ARM – SPECIAL
1-1/2 RB 1
1-5/8 H 41 1 24H 7. REACTION BARS
1-11-16 B 1-1/8 8. HEX BITS – SQUARE DRIVE WRENCH (TABLE 2.1-1)
1-13/16 H 46 1-1/8 30RB, 27H
1-7/8 B 1-1/4
9. HEX INSERT – HEX WRENCH
50 30H 10. HANDLES
2H 1-1/4
2-1/16 B 1-3/8 11. BRACKET - HANGING
55 36RB 12. CONSOLES – AIR OR HYDRAULIC
2-3/16 H 1-3/8
2-1/4 B 1-1/2 13. REDUCED THICKNESS HEX WRENCH
60 36H
2-3/8 H 1-1/2 14. SOCKETS WITH RETAINING PIN & RING
2-9/16 H 65 1-5/8 42RB 15. WRENCH, SPANNER, FRONT CAP:
2-5/8 B 1-3/4
2-3/4 H 70 1-3/4 42H MODEL PART NUMBER
2-13/16 B 1-7/8 a. RSL2 RSL2-3TOOL
2-15/16 H 75 1-7/8 48RB b. RSL4B RSL4-3BTOOL
3B 2 c. RSL6 RSL6-3TOOL
- -
3-1/8 H 2 d. RSL8 RSL8-3TOOL
80 48H e. RSL14A & B RSL14-3ATOOL
85 56RB f. RSL20 RSL20-3TOOL
3-3/8 B 2-1/4
3-1/2 H 2-1/4 16. COVER ASS’Y, PWR HD SPLINE (RSL00-700S):
90 56H
3-3/4 B 95 2-1/2 64RB MODEL PART NUMBER
3-7/8 H 2-1/2
a. RSL2 RSL2-700S
100 64H b. RSL4 RSL4-700S
4-1/8 B 105 2-3/4 72RB
4-1/4 H 2-3/4
c. RSL6 RSL6-700S
d. RSL8 RSL8-700S
110 72H
4-1/2 B 3 e. RSL14 RSL14-700S
115 80RB f. RSL20 RSL20-700S
4-5/8 H 3 g. RSL30 RSL30-700S
120 80H
4-7/8 B 3-1/4
5H 3-1/4
130 90RB
5/1/4 B 3-1/2
135 90H
5-3/8 H 3-1/2
145 100RB
5-3/4 H 3-3/4
150 100H
6B 4
6-1/8 H 4
R = REGULAR HEX, H = HEAVY HEX,
B = BOLT OR CAP SCREW

SECTION 12.0 - NOTES

SECTION 12.0 – NOTES (Continued)

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.

RSL Tools Operation and Maintenance Manual: Hex Wrench Square Drive Wrench SET SET

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RSL Tools Operation and Maintenance Manual: Hex Wrench Square Drive Wrench SET SET

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W2

HEX WRENCH SQUARE DRIVE WRENCH

Document Ref: W-ENG-5525-056

W-ENG-5525-056 (rev. AD) Page 2 of 40 ENG US

SECTION 1.0 - RSL TOOL SAFETY

Set-up proper tool reaction!

High hydraulic pressure hazard, 10,000 psi (690 bar)!

Immediately replace damaged hoses.

Keep clear of pinch points!

W-ENG-5525-056 (rev. AD) Page 3 of 40 ENG US

SECTION 1.0 - RSL TOOL SAFETY (continued)

Do not subject any equipment, tool, or accessory to impact!

Always assess risks and mitigate hazards

SECTION 1.1 - GENERAL SAFETY

Work with a valid permit when required.

Do not walk under a suspended load.

Follow site smoking rules as required.

W-ENG-5525-056 (rev. AD) Page 4 of 40 ENG US

SECTION 1.2 - RSL TOOL SAFETY – PUMP TAG

OPERATOR MUST READ ENGAGEMENT

PINCH POINTS. NEVER REACT

DO NOT STRIKE HEX WRENCH HEADS

LEADING THE WAY

W-ENG-5525-056 (rev. AD) Page 5 of 40 ENG US

SECTION 2.0 - SPECIFICATIONS - SQUARE DRIVE TOOLS

W-ENG-5525-056 (rev. AD) Page 6 of 40 ENG US

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

SECTION 2.2 - SPECIFICATIONS - HEX WRENCH

W-ENG-5525-056 (rev. AD) Page 8 of 40 ENG US

W-ENG-5525-056 (rev. AD) Page 9 of 40 ENG US

SECTION 2.3 - SPECIFICATIONS

PRESSURE / TORQUE CONVERSION CHART FOR RSL TOOLS

W-ENG-5525-056 (rev. AD) Page 10 of 40 ENG US

SECTION 3.0 SECTION 4.0 – RSL TERMS &

FIGURE 4.0–1 TERMS

W-ENG-5525-056 (rev. AD) Page 11 of 40 ENG US

SECTION 4.0 (continued)

Hex Wrench Head

QD’s for Power Head Hoses Hex Wrench Set

Square Drive Wrench Head

W-ENG-5525-056 (rev. AD) Page 12 of 40 ENG US

W-ENG-5525-056 (rev. AD) Page 13 of 40 ENG US

SECTION 4.0 - TERMS & BOLTING SECTION 5.0 - PLANNING

2. When required bolted joint pre-load accuracy is high:

W-ENG-5525-056 (rev. AD) Page 14 of 40 ENG US

SECTION 5.0 Warning! To avoid injury or tool damage

W-ENG-5525-056 (rev. AD) Page 15 of 40 ENG US

3. TIGHTEN METHOD 3 – Stud Elongation Tightening

W-ENG-5525-056 (rev. AD) Page 16 of 40 ENG US

SECTION 6.1.1 (cont.) Figure 6.1.2-1 Notes:

(c) 4th & Final Stage -

W-ENG-5525-056 (rev. AD) Page 17 of 40 ENG US

SECTION 6.2 (continued)

W-ENG-5525-056 (rev. AD) Page 18 of 40 ENG US

SECTION 6.3 (continued)

6. Contact Hydratight Customer Service or Engineering for

Note: Arrow(s) point to required gap. FIGURE 6.3-3

W-ENG-5525-056 (rev. AD) Page 19 of 40 ENG US

SECTION 6.3 (continued)

W-ENG-5525-056 (rev. AD) Page 20 of 40 ENG US

SECTION 6.4 (continued)