The document describes the jGun pneumatic torque wrench, a device designed for safely and accurately delivering torque to fasteners. It also covers the jGun Dual Speed Plus variant, the Filter/Regulator/Lubricator (FRL) Unit, and the HYTORC Reaction Washer system.
Function Description
The jGun pneumatic torque wrench utilizes a patented planetary gearbox torque multiplier system to apply torque to fasteners. It is designed to stall out safely once the final torque value is reached, ensuring the fastener is tightened to specification. Unlike impact wrenches, the jGun applies torque between the fastener and a reaction surface, preventing working torque from being transmitted to the operator.
The jGun Dual Speed Plus offers the added functionality of selecting between two speeds: high speed for rapid rundown and maximum torque for final tightening. This allows for efficient operation by quickly running down nuts and then applying precise torque.
The Filter/Regulator/Lubricator (FRL) Unit is an essential component that works in conjunction with the jGun. Its primary functions are to:
- Remove water and foreign material from the air supply.
- Regulate the air pressure to the jGun.
- Mix pneumatic tool oil into the air to lubricate the jGun's internal components.
The HYTORC Reaction Washer system is an innovative alternative to traditional reaction arms. It is a hex-shaped washer that fits under a standard nut and is used with a double-layered (concentric) socket. The inner socket turns the nut, while the outer socket reacts on the washer. This system aims to eliminate external moving parts, increase worker safety, and provide a universal reaction point, thereby removing the need for custom-designed reaction arms. It also helps prevent the bolt from turning, eliminating the need for back-up wrenches, and improves bolting accuracy by eliminating side-load and equalizing surface friction.
Important Technical Specifications
jGun Pneumatic Torque Wrench:
- Torque Output: Up to 8,000 ft-lbs.
- Torque Multiplier Ratio: Up to 1450:1.
- Warranty: One-year limited warranty covering defects in workmanship and materials.
- Accuracy: Stated accuracy of +/- 5% when properly maintained.
Air Supply Requirements (for jGun and FRL Unit):
- Air Line Diameter: Minimum 1/2-inch.
- Air Pressure: Minimum 90 psi at 30 cfm.
- Hose: Must use the 12' hose provided with the FRL unit for connection to the jGun to ensure durability and accuracy.
FRL Unit:
- Gauges: Analog gauges are standard; digital gauges are not recommended for certain applications.
Standards Compliance:
The jGun and its operation comply with several EN, EN-ISO, and ISO standards, including:
- EN ISO 12100-1:2011
- EN ISO 12100-2:2011
- EN ISO 14121-1:2007
- EN ISO 11148-6:2012
- EN ISO 4414:2010
- EN 61310-2:2008
- EN 61310-3:2008
- ISO 3744:2011
- BS EN 82079-1:2012
Usage Features
jGun Operation:
- Reaction Arm/HYTORC Washer: The jGun requires either a reaction arm or the HYTORC Reaction Washer system to absorb counter-rotational force. Standard and custom reaction arms are available.
- Socket Installation: Sockets are placed onto the jGun barrel and secured with a locking pin and retaining ring.
- Safety Lever: A patented safety mechanism requires the lever to be depressed while pulling the trigger, keeping the operator's hands away from pinch points.
- Drive Direction: A directional lever on the back cover allows for easy switching between tightening (forward) and loosening (reverse) directions. The lever must be fully engaged before operation.
- Fastener Engagement: The reaction arm must be in direct contact with an immovable object, or the HYTORC Washer Driver must be engaged over the reaction washer, before tightening. The jGun barrel and socket must be in a straight line with the stud and fully engaged onto the fastener.
- Torque Application: Torque is applied by depressing the trigger until the socket stops turning and air bypasses the motor.
- Loosening Fasteners: For loosening, the FRL pressure should be set to maximum PSI, and the torque wrench set to the loosening direction.
jGun Dual Speed Plus Operation:
- Speed Selection: Features a clutch wheel on the barrel for shifting between high speed (for rundown) and maximum torque modes.
- Shifting Mechanism: Shifting is achieved by twisting the shifter collar. Pushing the collar down and turning counter-clockwise engages high speed; turning clockwise returns to torque mode.
- Safety Precaution (Shifting): Crucially, gun modes must NEVER be switched on the fly. The tool must be stopped, and the shifter fully engaged in either forward or backward position. Visual indicators (red line for "torque," blue line for "run down") confirm full engagement.
FRL Unit Usage:
- Air Flow Direction: The unit must only be operated with air flow moving in the direction indicated by arrows on top of the unit.
- Pressure Adjustment: Air pressure is adjusted using a regulator knob while the jGun is running. The gauge displays a slightly higher pressure when the tool is stopped, which is normal. A pressure/torque conversion chart is provided to determine the required air pressure for desired torque.
- Lubricator Flow Adjustment: The oil flow from the lubricator is adjusted by turning a knob while the tool is running, aiming for one drop every ten seconds through the acrylic view-glass.
HYTORC Reaction Washer Usage:
- Proper Sizing: Use the correct size HYTORC Washer for the bolts and nuts.
- Cleanliness: The joint, fasteners, and HYTORC reaction washer must be properly inspected, cleaned, and dried, free of oil or grease.
- Lubrication: The retaining nut installed on top of the HYTORC Washer must be lubricated according to specifications on the torque/bolt load conversion chart.
- Installation: The HYTORC Washer socket driver assembly is installed over the nut and HYTORC Washer. The jGun is then used to tighten until the desired torque is reached.
Maintenance Features
General jGun Maintenance:
- Regular Inspection: Inspect all jGun components, reaction arms, and accessories for damage or wear before each use. Replace worn or damaged parts.
- Storage: Store the jGun and accessories in the supplied plastic storage case when not in use, avoiding high humidity or large temperature variations.
- Professional Repair: jGun maintenance and repair must be performed by a qualified pneumatic technician.
- No Modifications: Modifying the jGun or its accessories is dangerous and voids the warranty.
- Calibration: Torque Gun Company offers calibration services for a minimal fee to verify torque accuracy, especially for critical applications. The stated accuracy is +/- 5% with proper maintenance.
Hoses and Fittings Maintenance:
- Visual Inspection: Visually inspect air lines and fittings before each tool use.
- Replacement: Replace worn or leaking air lines.
- Tightening: Tighten leaky fittings, but avoid over-tightening to prevent permanent thread failure. Loose or over-tightened fittings can cause personal injury and tool damage.
Air Motor Lubrication:
- Procedure: Turn the jGun upside down, disconnect the air hose, pour approximately one ounce of air tool oil (or spray lubricant) into the hose coupling, reconnect the hose, and operate the gun while standing clear of the exhaust opening. Excess lubricant will release upon initial operation.
- Recommended Oil: MARVEL AIR TOOL OIL is recommended.
FRL Unit Maintenance:
- Essential Use: The FRL Unit is mandatory for jGun operation; using the jGun without it voids the warranty and can damage the air motor and gearbox.
- Filter Reservoir: Empty the filter reservoir of water and sediment before each use. This can be done by pushing the release valve or by detaching the reservoir (push down black square button, twist, pull down).
- Lubricator Reservoir: Fill the lubricator reservoir with pneumatic tool oil (provided with the FRL unit) before each use, ensuring it is about two-thirds full. To refill, push down the black square button, twist, pull down, fill, then reattach by aligning lines, pushing up, and twisting to lock.
- Air Motor Protection: Incorrect lubricator setting (insufficient oil flow) can lead to motor seizure.
- Air Supply Check: Before connecting an external air supply, check the air pressure gauge on the FRL unit to ensure it's set at "zero" pressure. A damaged gauge can lead to inaccurate torque.
- Coupler Inspection: Check male and female couplers for dirt, as dirt entering the jGun can damage the air motor.
jGun Gear Box Maintenance:
- Screw Inspection: Check the jGun's gearbox for loose or missing screws. Do NOT operate if screws are loose or missing, as serious damage may occur. Use LOCTITE 262 on screws.
- Gasket Check: Check the back cover gasket for air leaks, which can result in inaccurate torque.
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