MANUAL TNS Series Nut Splitter

TNS Series OPERATION AND MAINTENANCE MANUAL TNS Series Nut Splitter MODELS TNS-012, TNS-100, TNS-104, TNS-108, TNS-112, TNS-200, TNS-208, & TNS-300 1025 Conroy Place, Easton, PA. 18040 U.S.A. Phone: +1 610-250-5800 Fax: +1 610-250-2700 Toll Free: 1-888-TORCUP-1 Email: sales@torcup.com Website: www.torcup.com 1

Operational and Maintenance Manual for TorcUP TNS Series Nut Splitters Version 1: 2016 December NOTICE The TorcUP TNS Series Hydraulic Nut Splitter cuts nuts, leaving the bolt and threads undamaged when operated correctly. Eliminating the need for hammers, torches and other less predictable options, the TNS Series Nut Splitter is durable, reliable and safe. Its simple design and wide range make it the most in demand nut splitter available. The TNS Series Nut Splitter is made in the USA and provides a simple solution to what can be a difficult issue. TorcUP Inc. is not responsible for customer modification of tools for applications on which TorcUP Inc. was not consulted. WARNING IMPORTANT SAFETY INFORMATION ENCLOSED. READ THIS MANUAL BEFORE OPERATING TOOL. IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS MANUAL INTO THE HANDS OF THE OPERATOR. FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY. Made In USA Eight Models From 1/2 to 3 (12mm - 76mm) Field Replaceable Cutting Blades Genuine Compact and Ergonomic TorcUP Design Maximum Operating Pressure: 10,000 psi The use of other than genuine TorcUP replacement parts may result in safety hazards, decreased tool performance, increased maintenance, and may invalidate all warranties. Repairs should be made only by authorized personnel. Consult your nearest TorcUP Authorized Service Center. Refer All Communications to the Nearest TorcUP Office or Distributor. For Technical Support & Information Contact: TorcUP Inc. 1025 Conroy Place, Easton, PA 18040 USA Phone: +1 610-250-5800 Fax:+1 610-250-2700 email: sales@torcup.com 2

WARNING FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY Do NOT Exceed Maximum Pressure. See Torque Chart with Tool. Damage May Occur. Do not use damaged, frayed or deteriorated hydraulic hoses and fittings. Always wear eye protection when operating or performing maintenance on this tool. Always wear ear protection when operating this tool. Do not carry the tool by the hose. Keep body stance balanced and firm. Do not overreach when operating this tool. USING THE TOOL Keep hands, loose clothing and long hair away from the reaction point and working area during operation. Do not attempt to support the tool with your hands during operation. Always wear the appropriate protective equipment, such as safety glasses and gloves. Do not allow the hydraulic hoses to kink, twist curl or bend so tightly that the oil flow within is blocked or reduced. Creating pressure beyond 10,000 psi rated capacity may result in injury. Correct Wrong Never place any body part between the tool and the equipment being worked on. Figure 1 This tool is not designed for working in explosive atmosphere. Never attempt to grasp a pressurized hose that is leaking. Do not split nuts into sections smaller than half of the nut. Smaller pieces may fly off the nut if it is split in small sections. See Figure 1. Depending on the working environment, your local health and safety regulations may require you wear protective gear (i.e. safety shoes, hard hat, gloves, coveralls, etc.). In case external forces are exerted on the equipment, non-compliance with these regulations may result in injury. EAR PROTECTION MUST BE WORN WHEN OPERATING THIS TOOL. 3

OPERATING THE TOOL POWER REQUIREMENTS The TNS Series Nut Splitter is a single-acting, hydraulic-advance, spring return unit. All models require a hydraulic pump that delivers 10,000 psi (700 bar) of pressure. Any type of hydraulic pump may be used; including air, electric, and hand driven pumps. Any one of our pumps listed below will operate all models of our nuts splitters. Recommended combinations are listed below. Hydraulic pumps that maybe be used with the TNS Series Nut Splitter: Pump Model Power Type Nut Splitter Model Range HP100 MANUAL-HAND TNS-012 - TNS-300 AP100 AIR/HYDRAULIC TNS-012 - TNS-300 EP100 ELECTRIC/HYDRAULIC TNS-012- TNS-300 AP100 Single Acting / Single Hydraulic Port Pressure relief valve for overload protection Required air pressure range: 110-175psi. / 7.5-12 bar Dust cover protection for the release control valve High strength reinforced alloy reservoir Maximum working pressure: 10,000 psi / 700 bar HP100 Single Acting / Single Hydraulic Port Two speed operation which reduces user fatigue Internal pressure relief valve for overload protection Large oil capacity to power a wide range of tools Constructed of high strength lightweight aluminum alloy Functions in horizontal and vertical positons Maximum working pressure: 10,000 psi / 700 bar EP100 Single Acting / Single Hydraulic Port Quiet operation meets OSHA regulations (80dBA) 2 speed operation allows for faster cylinder advance Internal filter keeps contamination from damaging pump 10 ft. remote pendant switch to control motor on/off Maximum working pressure: 10,000 psi / 700 bar 4

OPERATING THE TOOL All hydraulic pumps include the necessary fittings and hoses. If a hydraulic pump is not being used to power the TNS Nut Splitter, the following requirements must be met: NUT SPLITTER MODEL RANGE HOSE RATED RECOMMENDED PUMPS TNS-012 - TNS-100 10,000 psi AIR/ELECTRIC/HAND TNS-104 - TNS-108 10,000 psi AIR/ELECTRIC/HAND TNS-112 - TNS-200 10,000 psi AIR/ELECTRIC/HAND TNS-208 - TNS-300 10,000 psi AIR/ELECTRIC/HAND OPERATING THE TNS SERIES NUT SPLITTER 1. Lubricate the tip of the chisel with an anti-seize lubricant before each cut. 2. Connect the female quick disconnect coupler to the nut splitter s male coupler. 3. Place the nut splitter over the nut, insuring that the anvil lies flat on the surface of the flange, the nut is against the flat of the anvil across from the chisel, and the chisel is centered on a flat of the nut. See Figure 2. 4. Slowly extend the chisel until it makes contact with the nut. Check that the chisel is centered on the nut face. 5. Continue to apply hydraulic pressure to the cylinder until the nut is severed. A loud pop will occur, signifying that the nut has been split. 6. For complete removal, it may be necessary to cut the opposite face of the nut. If so, rotate the nut 180 degrees (a hammer or oversized wrench may be necessary to rotate nut), relubricate the chisel, and repeat steps 3 through 5. Figure 2 LIMITED WARRANTY The product is warranted against defects in workmanship and materials for 13 months from date of shipment to customer. Warranty does not cover ordinary wear and tear, abuse, misuse, overloading or altered products. 5

TNS Series Nut Splitter Parts List MODEL # TNS-012 TNS-100 TNS-104 ANVIL PART # TNS-012-01 TNS-100-01 TNS-104-01 CHISEL PART # TNS-10T-CHISEL TNS-10T-CHISEL TNS-30T-CHISEL CYLINDER PART # TNS-012-CYL TNS-100-CYL TNS-104-CYL MODEL # TNS-108 TNS-112 TNS-200 ANVIL PART # TNS-108-01 TNS-112-01 TNS-200-01 CHISEL PART # TNS-30T-CHISEL TNS-50T-CHISEL TNS-50T-CHISEL CYLINDER PART # TNS-108-CYL TNS-112-CYL TNS-200-CYL 6

TNS Series Nut Splitter Parts List MODEL # TNS-208 TNS-300 ANVIL PART # TNS-208-01 TNS-300-01 CHISEL PART # TNS-75T-CHISEL TNS-75T-CHISEL CYLINDER PART # TNS-208-CYL TNS-300-CYL HANDLE PART # TNS-NSH TNS-NSH 7

TNS Series Nut Splitter Technical & Dimensional Data Part Number Range (in) Range (mm) A B TNS-012 1/2-3/4 12-19 mm 2.00 / 50.8 mm 0.40 / 10.2 mm TNS-100 13/16-1 20-25 mm 2.25 / 57.2 mm 0.40 / 10.2 mm TNS-104 1 1/16-1 1/4 27-32 mm 3.75 / 95.3 mm 1.01 / 25.7 mm TNS-108 1 5/16-1 1/2 33-38 mm 3.75 / 95.3 mm 1.12 / 28.4 mm TNS-112 1 9/16-1 3/4 39-45 mm 4.50 / 114.3 mm 1.38 / 35.1 mm TNS-200 1 13/16-2 46-50 mm 5.00 / 127.0 mm 1.50 / 38.1 mm TNS-208 2 1/16-2 1/2 50-63 mm 6.25 / 158.8 mm 1.50 / 38.1 mm TNS-300 2 9/16-3 63-76 mm 6.50 / 165.1 mm 1.54 / 39.1 mm Part Number C D E Flat TNS-012 0.63 / 16 mm 6.71 / 170.4 mm 2.76 / 70.1 mm 1.11 / 28.2 mm TNS-100 0.72 / 18.3 mm 6.94 / 176.3 mm 2.77 / 70.4 mm 1.30 / 33.0 mm TNS-104 1.13 / 28.7 mm 11.79 / 299.5 mm 5.04 / 128.0 mm 2.63 / 66.8 mm TNS-108 1.13 / 28.7 mm 12.19 / 309.6 mm 5.05 / 128.2 mm 2.53 / 64.3 mm TNS-112 1.25 / 31.8 mm 13.95 / 354.3 mm 5.69 / 144.5 mm 3.23 / 82.0 mm TNS-200 1.50 / 38.1 mm 14.23 / 361.4 mm 5.67 / 144.0 mm 3.52 / 89.4 mm TNS-208 2.00 / 50.8 mm 18.19 / 462.0 mm 7.73 / 196.3 mm 3.63 / 92.2 mm TNS-300 2.50 / 63.5 mm 18.57 / 471.7 mm 7.69 / 195.3 mm 4.50 / 114.3 mm 8

MAINTENANCE MAINTENANCE Treat the TNS Nut Splitter like any other precision tool. Keep it clean and free from moisture. Wipe it down with a cloth or paper towel after each use. The following should be done on a regular basis to increase the longevity of the tool: 1. Always lubricate the chisel point with anti-seize lubricant before each cut. 2. Do not let the chisel get dull. Sharpen the chisel with a hand whetstone or slowly with a grinder. Be sure to keep the chisel wet while sharpening. 3. Replace the dust covers on the quick disconnects and thread protectors on the cylinder after each use. 4. Store the NUT SPLITTER in its custom made toolbox or case. 5. The contact points between the piston rod and the anvil need to be greased. Moly marine grade grease is recommended. Regrease each time the tool is taken apart. It is also recommended to regrease after 100 strokes. All the materials used in the TNS Nut Splitter were chosen through extensive research. All parts are rated for their intended use, and do not need field repair. Improper assembly, modification or substitution of other parts is unsafe, will void the warranty, and could damage the tool. ASSEMBLY INSTRUCTIONS The TorcUP TNS Nut Splitter is delivered fully assembled and ready to use. The Nut Splitter consists of a two-piece threaded body, piston, return spring, cutting chisel and quick connect coupler. If it is necessary to disassemble the TNS Nut Splitter for repairs, reverse the disassembly instructions carefully when re-assembling. Failure to follow these instructions may damage one or more components. DISASSEMBLY INSTRUCTIONS Should it become necessary to disassemble the TNS Nut Splitter, follow these steps: 1. Unscrew the coupler from the cylinder. Hold the cylinder over a container to catch any oil left in the cylinder 2. Remove the side set screw. 3. Remove the chisel cap head screw. 4. Slide the chisel out from anvil. 5. Loosen the locking setscrew in the anvil to allow the cylinder to be unscrewed from the anvil. Note: The 10-ton cylinder (TNS-012 and TNS-100) can be unscrewed by hand. The larger cylinders have cap head screws to aid in unscrewing the cylinder. 6. Remove the return spring. 7. Remove the piston. If the piston is tight in the housing and difficult to remove, inject air into the cylinder while holding it over a container that will not damage the piston when expelled. 8. Inspect the piston O-ring. Replace if necessary. 9

TROUBLESHOOTING Problem Cylinder does not hold pressure Possible Causes 1. Cylinder seal leaking 2. Leaking connection 3. Pump malfunction Possibly Solutions 1. Change cylinder 2. Tighten connections 3. Change pump Cylinder does not hold advance or advances partially Cylinder advances slowly Cylinder does not retract, retracts Slowly or retracts partially 1. Pump release valve open 2. Not enough oil in pump 3. Air in system 4. Couplers not tightened 5. Pump reservoir too small 1. Leaking connection 2. Restricted hydraulic hose or fitting 3. Loose coupler 4. Pump flow rate too slow 1. Pump release valve closed 2. Coupler not fully closed 3. Blocked hydraulic hose 4. Damage retraction spring in cylinder 5. Pump reservoir overfilled 1. Close valve 2. Add oil 3. Bleed air 4. Fully tighten couplers 5. Change pump (use one with a larger reservoir) 1. Tighten connections 2. Change hoses or 3. Tighten couplers 4. Change pump (use one with a faster flow rate) 1. Open valve 2. Close coupler 3. Replace hoses 4. Replace spring 5. Remove excess oil Chisel does not penetrate nut 1. Inadequate pump pressure 2. Chisel edge blunt 3. Housing not fully threaded 1. Increase to 10,000 psi 2. Sharpen or replace chisel 3. Thread housing all the way 10

SAVE THESE INSTRUCTIONS DO NOT DESTROY NOTES: 1025 Conroy Place, Easton, PA. 18040 U.S.A. Phone: +1 610-250-5800 Fax:+1 610-250-2700 Toll Free: 1-888-TORCUP-1 Email: sales@torcup.com Website: www.torcup.com