2018-2019 Guide to the Use and Maintenance of Pulse Torque Tools

Pulse tools are built for a reason: to deliver high torque at high speeds. Because they absorb reaction, they can be safely used to fasten nuts or screws at torque values far above what continuous air or electric screwdrivers can handle. Consider their relative production values:

• Whereas the torque delivered by other air and electric tools is measured in pound force-inches, pulse tools are measured in pound force-feet. That’s an order of magnitude more power than other tools create.
• A pistol grip air screwdriver may produce ~150 lbf-in. A pistol grip pulse screwdriver, when measured on the same scale, puts out ~3980 lbf-in. That’s 25 times more torque.

If not channeled properly, these amounts of torque can damage your workpiece, harm the tool itself, or injure the operator. The failure of the application, tool accessories, or the tool can create high-velocity projectiles, risking injury to the immediate operator and nearby personnel.

Other hazards are present when using torque tools as well. The high-speed drive poses entanglement issues for operators, as well as creating the possibility of crushing, impact, cutting, abrasive, or heat-related injuries. The weight of the tool and the force of the drive may lead to repetitive motion injuries. The tool’s air or hydraulic lines create tripping hazards, as well as whipping injuries or damage. Tool usage can create dust and fumes or disturb existing dust particles. Pulse tools can generate noise levels high enough to cause hearing loss or tinnitus over time, and the vibration from tool use can cause nerve damage or impede blood flow to the hands and arms.

However, most, if not all, of these hazards can be mitigated and prevented by the proper use and maintenance of your pulse tools. Adhering to best practices reduces the risk of operator injury and damage to your tool or workpiece. Taking time to understand the right way to use and service a pulse tool will save significant amounts of time and money.

The first rule of tool use is, “know thy tool.” In order to properly handle a high-torque pulse tool, an operator should be trained in certain basic principles, such as:

• Basic operation and intended use of the tool.
• Required personal protective equipment and its usage.
• Recognition of common issues, such as no shut-off, premature shut-off, incomplete rundowns, low torque output, inconsistent torque output, and low RPMs.
• The proper procedure for air hose connection, disconnection, and storage.
• Recognition of tool damage, such as leaks, loose connections, cracks, and dents.
• Recognition of air line damage, such as leaks, loose connections, cuts, scrapes, gouges,  bulges, cracks, or rot.

It shouldn’t take a seasoned operator to recognize obvious issues with a tool before using it. The initial training for operators should include information on common issues and the established procedure for identifying the need for repairs. Operators should have ready access to the tool’s instruction manual and should be expected to understand the operational guidelines before using the tool.

When not in use, a pulse tool should be stored in its case, in a cool, dry, secure location. The tool must be correctly set up and taken down before and after every use. This is an ideal time to inspect the tool to ensure it is in good working condition and set to the appropriate torque value. It’s also a good opportunity to clean the tool, removing any excess lubricant or dust.

When it is not in good working condition, your pulse tool should be flagged for maintenance. If the torque value is incorrect, it must be adjusted using the methods detailed in the instruction manual. The air line and air compressor should be inspected as well. After you have performed your inspection, follow these steps:

• Ensure personal protective equipment—including gloves, eye protection, and ear protection—is adequate and in place. Loose clothing, jewelry, or hair should be removed or secured to prevent entanglements. Eyewear should be impact resistant and rated based on assembly.
• Connect the air hose to the generator and the pulse tool, then secure the connections. The air hose should be 5m or less. Specific guidelines for hose length and diameter may come with your tool. Check connections on any appliances, such as air flow regulators.
• With airflow toggles closed, start the generator. Bring air pressure to the appropriate level. Standard air inlet pressure is 85PSI, or (6.2kg/cm2).
• After the tool is secured, open the airflow toggles first to the hose, then to the tool.
• Always operate the tool with both hands.
• Do not force the tool beyond its capabilities
• Maintain a balanced, comfortable posture and secure footing, and be ready to counteract any sudden movements.
• To stop work at the end of a shift, make repairs, or change accessories, shut off the air supply, drain the hose of pressure, then disconnect the tool.
• Inspect the tool for damage or wear incurred during the shift.
• Store the tool in a designated area, in accordance with the manufacturer’s and company guidelines.

In addition to the care that must be taken during the normal operation of the tool, certain other conditions warrant special remediation. For example, if the workpiece tends to ring, significantly increasing the volume of the workplace, dampening materials should be used. If a torque arm is requested, try suspension-type arms. Caution should be used in unfamiliar surroundings, where electric or gas lines may be present. In cold conditions, warm clothing will reduce potential injuries from vibration.

Lastly—this one’s for the rookies—don’t carry an air tool by the hose. You’ll wreck it, and then someone’s going to have to fix it.

A little spit and polish can make an old tool feel brand new. By keeping up with your tool’s routine maintenance, you can extend its lifetime and reduce accidents. While the specific requirements for each pulse tool depends on series, application, and usage, certain maintenance needs are shared by all, including oil changes and periodic inspections of the soft and hard parts of the tool.

Both the soft and hard parts of your pulse tool will require inspections at regular intervals. As with oil changes, these intervals are determined by the pulse-seconds that your tool is in use.

The soft parts of your tool should be inspected with your oil change, at 250,000 pulse-seconds. The parts will be referenced as the “repair kit” in the parts list document which comes with your tool. Replacement parts will be included in the repair kit. This inspection should take place at maximum intervals of six months, regardless of use. The soft parts of your tool should also be replaced entirely during your second servicing of the tool, at 500,000 pulse-seconds. This cycle then repeats. The labels on your tool should be inspected at least as often as the soft parts, and worn out or illegible labels should be replaced.

The hard parts of your tool will be replaced less frequently than the soft parts. They should be inspected once every 500,000 pulse-seconds or once to twice yearly, at a minimum. These parts will be detailed in the service kit that comes with your tool. Parts should be replaced when they show signs of wear or damage. Instructions on the assembly and disassembly of the tool will be included in the instruction manual.

Each time the tool is inspected, it should be cleaned as well. This means wiping away excess lubricants and removing any dust or grime. When doing so, avoid corrosive cleaners and overly stiff brushes. The pulse tool should be kept away from rain or damp conditions and stored in a dry place. The tool’s air supply should always be clean, dry, lubricated, and supplied at the correct pressure. Tools which fail before their scheduled inspection must be rebuilt using the repair and service kit. Their inspection interval should then be reduced.

Only allow trained and qualified technicians to inspect or service your pulse tools. Modifications of any kind should not be allowed. It’s also wise to keep records of all inspections and service in a readily accessible location. These records can be consulted for future maintenance needs, as well as to prove regulatory or quality compliance. It’s important to read and understand the terms of the manufacturer’s warranty, and defective tools covered by warranty should be sent to the manufacturer.

Pulse tools are efficient, effective instruments for rapid assembly of high-torque fasteners. Their use can speed up an assembly line, ensure accurate torque delivery, and reduce ergonomic stress on operators. In many high-paced production industries, pulse tools are indispensable in daily operations. The best way to make sure your pulse tools can be counted on is to use them well and maintain them properly. After all, if you treat your tools right, they’ll return the favor.