OPERATION & SERVICE

INSTRUCTIONS FOR

MODEL PD 6501
TORQUE WRENCH

POWER-DYNE LLC
BIDWELL INDUSTRIAL GROUP
2055 SOUTH MAIN STREET
MIDDLETOWN, CT 06547-6151

TELEPHONE: (860)343-6640
FAX: (860)343-6642
EMAIL: [email protected]

JULY, 2002
 TABLE OF CONTENTS
SECTION TITLE PAGE
I INTRODUCTION AND DESCRIPTION

1-1 INTRODUCTION 4

1-2 REPORTING ERRORS 4

1-3 PURPOSE 4

1-4 CAPABILITIES & CHARACTERISTICS 4

1-5 ITEMS FURNISHED 4

1-6 ITEMS AVAILABLE 4

1-7 SPECIAL TOOLS & TEST EQUIPMENT 4

1-8 WARRANTY 4

1-9 GENERAL DESCRIPTION 5

1-10 PROTRACTOR OPERATION 5

1-11 RATCHET OPERATION 5

II SAFETY PRECAUTIONS

2-1 SAFETY 5

2-2 DAMAGE TO EQUIPMENT 5

III PREPARATION FOR USE & INSTALLATION

3-1 GENERAL 6

3-2 ACCESSORIES 6
IV GENERAL THEORY OF OPERATION

4-1 GENERAL 6
V OPERATING INSTRUCTIONS

5-1 WRENCH OPERATION 6

5-2 RATCHET OPERATION 6

5-3 USE OF A REACTION BAR 7

5-4 POWER DRIVES 7

VI MAINTENANCE

6-1 TROUBLE SHOOTING 7

6-2 CLEANING 7

6-3 INSPECTION 8

6-4 LUBRICATION 8

2
 SECTION TITLE PAGE

6-5 DISASSEMBLY 8

6-6 REASSEMBLY 10

6-7 PERFORMANCE EVALUATION 12

6-8 CALIBRATION 12
VII PREPARATION FOR SHIPMENT & STORAGE

7-1 GENERAL 14

7-2 PREPARATION FOR STORAGE 14

7-3 PREPARATION FOR SHIPMENT 14

VIII PARTS LIST

8-1 GENERAL 14
TABLES

1-1 SPECIFICATION PD 6501 15

6-1 TROUBLESHOOTING CHART 15

6-2 CALIBRATION SET POINTS & TOLERANCES ±2% 16

6-3 RECOMMENDED LUBRICANTS AND SEALANTS/ADHESIVES 16

FIGURES

1-1 PD 6501 POWER-DYNE TORQUE WRENCH 17

3-1 ADAPTER HOLE PATTERN & REACTION ADAPTER PLATE DESIGN 17

5-1.A INSTALLATION OF SOCKET AND DRIVE BAR 18

5-1.B INSTALLATION OF ADAPTER PLATE AND TORQUE PACK 18

5-1.C INSTALLATION OF TORQUE WRENCH ON ADAPTER PLATE 18

5-1.D ROTATING THE TORQUE WRENCH 18

5-3 TORQUE WRENCH & REACTION BAR INSTALLATION 19

6-1 PD 6501 WRENCH GREASE FITTINGS 20

6-2 AREA OF MOLY-COAT 20

6-3 PD 6501 EXPLODED VIEW 21

6-4 O-RING INSTALLATION 22

6-5 CALIBRATION ADJUSTMENTS 22

PARTS LIST

8-1 PARTS LIST PD 6501 MODEL TORQUE WRENCH 23

SECTION I
3
 INTRODUCTION AND DESCRIPTION
1-1 INTRODUCTION
This manual contains operating instructions, maintenance instructions, and parts lists for the Model PD
6501 Power-Dyne Torque Wrench (NSN 5120-01-003-6713) hereinafter called the wrench and the PD
6501-M1. The Power-Dyne Torque Wrench is designed and manufactured by the Power-Dyne LLC,
2055 South Main Street, Middletown, CT, 06457-6151.

1-2 REPORTING OF ERRORS

You can help this publication by calling attention to errors or recommending document improvements.
Your correspondence may be:

Mailed directly to: Faxed directly to: E-mailed directly to:

Power-Dyne LLC Power-Dyne LLC [email protected]
Bidwell Industrial Group Attn. QA Attn. QA
2055 South Main Street (860)343-6642
Middletown, CT 06457-6151
Attn. QA
Upon review a reply will be furnished directly to you.

1-3 PURPOSE
The wrench (reference Figure 1-1) makes it possible for an operator to apply a very high torque with a
minimum of effort. An input of 25 lb-ft produces an output torque of up to 6,500 lb-ft. This high rate of
mechanical advantage is achieved by a worm gear train that provides continuous, centrally-balanced,
output motion in either a clockwise (CW) or a counterclockwise (CCW) direction.

1-4 CAPABILITIES AND CHARACTERISTICS: (See Table 1-1)

1-5 ITEMS FURNISHED:

Each wrench is supplied with a heavy duty plastic carrying case, an input crank handle, and a 1 1/2 inch
square drive bar.

1-6 ITEMS AVAILABLE:

In addition to the items in 1-5, Power-Dyne has available for various torque applications adapter plates,
extension drives, breaker bars, reaction bars, and various pneumatic or electric motor drives. These are
available from Power-Dyne, numerous commercial sources, or they can be designed and manufactured
by the user for special torque applications.

1-7 SPECIAL TOOLS AND TEST EQUIPMENT:

No special tools are required for maintenance. Calibration is accomplished by using a calibration load
cell system with a system accuracy full scale of ±0.1%. For information concerning calibration tooling
contact Power-Dyne.

1-8 WARRANTY:
Subject to the limitations and conditions set forth below, the Seller warrants that items sold shall be free
from defects in material and workmanship for one year from date of sale. A defect under this warranty
must become apparent to the Buyer within ninety (90) days after receipt thereof by the Buyer. The
Seller’s liability under this warranty is limited to repair replacement of any product that does not comply
with the warranty pertaining thereto. The Seller shall, as to matters embraced within this warranty, be
relieved of all obligations and liability under this warranty if:

A. The defect is caused by exposure to conditions which exceed specified limitations; or

B. The product or any part thereof, is altered by persons not authorized by the Seller; or
C. The product is not operated or maintained in accordance with the Seller’s instructions and data.

1-9 GENERAL DESCRIPTION:

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 The wrench is composed of a balanced worm gear train contained in an aluminum housing, an input
drive spindle is located on the top front, and an output drive on the center rear. A torque indicator
consisting of a torque output gauge located on the front of the wrench coupled hydraulically to two
bellows transducers contained in a reaction adapter mounted on the rear. The reaction adapter is pivoted
on the rear of the wrench housing between four screws and four self-aligning buttons, so that a twisting
force placed on the adapter loads the bellows and produces a torque readout on the indicator gauge.

1-10 PROTRACTOR OPERATION

For applications where nut rotation is of greater importance than torque forces, a protractor and pointer
assembly is provided on the front of the wrench. The pointer is attached to the ratchet indexer to provide
a readout in degrees of output rotation when the drive is turned.

1-11 RATCHET OPERATION

The wrench incorporates a ratchet drive for right or left hand torque applications (tightening or loosening
hardware). The ratchet mechanism is set by clockwise (CW) or counterclockwise (CCW) rotation of the
ratchet indexer on the front of the wrench. A CW setting produces torque in a CW direction and a CCW
setting produces torque in a CCW direction.

SECTION II
SAFETY PRECAUTIONS

2-1 SAFETY
No special precautions need to taken in using the wrench. The small input force required to achieve high
output torque greatly reduces operator fatigue and eliminates the hazards associated with the use of
large, heavy levers or bars.

!WARNING!
CLEANING AGENTS
CLEANING SOLVENTS MAY BE TOXIC AND/OR FLAMMABLE. USE ONLY IN WELL VENTILATED
AREAS. AVOID PROLONGED CONTACT WITH SKIN OR INHALATION OF FUMES. DO NOT USE
SOLVENTS NEAR OPEN FLAME, IN AREAS WHERE VERY HIGH TEMPERATURES PREVAIL, OR
IN CLOSED AREAS.

USE OF COMPRESSED AIR TO DRY PARTS

DO NOT EXCEED 25 PSI NOZZLE PRESSURE WHEN DRYING PARTS BY BLOWING THEM OFF
WITH COMPRESSED AIR AGAINST YOUR SKIN.

2-2 DAMAGE TO EQUIPMENT:

A. It is difficult to damage the wrench when properly used. The wrench’s output drive bar is
designed to fail (twist) at torque levels below those that would cause damage. However, care
should always be taken when setting the ratchet mechanism to ensure the indexer has been
moved to its extreme CW or CCW position prior operating the wrench. The high torque
generated could seriously damage the wrench when the ratchet is not securely engaged. Never
use an impact drive as a power input as this will damage or substantially shorten wrench life.

B. Always observe design torque values during wrench operation. Excessive output torque can
damage threads or over-stress fasteners resulting damage or failure.

C. Ensure that fasteners are not cocked or otherwise improperly installed prior to torque application.
The wrench is designed to eliminate side loads. Every effort should be made to utilize an adapter
plate that provides a balanced couple for the work required.

SECTION III

5
 PREPARATION FOR USE AND INSTALLATION

3-1 GENERAL:
No special provisions are required to use the torque wrench. Details for use are contained in Section V,
Operating Instructions.

3-2 ACCESSORIES:
As previously stated, a wide variety of accessories are available from Power-Dyne, or various commercial
sources, or they can be designed and fabricated by the user for special torque applications. Refer to
Figure 3-1 for proper adapter design and clearance dimensions.

SECTION IV
GENERAL THEORY OF OPERATION

4-1 GENERAL INFORMATION:

The wrench applies torque through the mechanical advantage of a worm gear train. Force applied to the
crank handle is transmitted through the gear train to the output shaft. A torque indicator assembly, which
incorporates a pair of hydraulic bellows transducers, is so mounted that when coupled to an adapter
plate, causes reaction forces to be applied to the bellows transducers and transmitted to the indicator
gauge on the face of the wrench. The ratchet drive makes it possible apply torque in a right or left hand
application (tighten or loosen fasteners). The protractor and pointer provide a measure of output rotation
for those applications where rotational measures are important or required.

SECTION V
OPERATING INSTRUCTIONS

5-1 WRENCH OPERATION:

The following provides a simplified example of wrench use and can serve as the basis for operating in a
variety of torque applications.

A. As shown in Figure 5-1.A install a nut on a stud (fastener), and run it down until snug by hand or
with a conventional wrench. Install a socket and the wrench drive bar.

B. Select a suitable adapter plate and install it over the drive bar and socket as shown in Figure 5-
1.B. Ensure that the side arms of the adapter engage the sides of the beam.

C. Install the wrench over the drive bar and adapter plate ensuring the two reaction pins on the
wrench reaction arm fully engage the holes in the adapter plate as shown in Figure 5-1.C. It may
be necessary to rotate the wrench slightly to align the reaction pins properly with the adapter
plate as shown in Figure 5-1.D.

5-2 RATCHET OPERATION:

The following describes the ratchet operation for a right hand thread.

A. Turn the ratchet indexer in a CW direction (approximately 1/8 turn) until the red mark on the
indexer lines up with the red mark on the output drive shaft.

B. Turn the crank handle CW direction until the backlash in the gear train is eliminated and the
adapter plate turns to engage the sides of the beam firmly. Continue to turn the crank handle
until the desired torque value can be read on the indicator gauge.

C. If a measure of fastener rotation is desired, set the pointer on the ratchet drive to zero on the
protractor after applying initial torque, then turn the torque wrench crank handle while observing
the protractor reading.

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 D. To remove the wrench, rotate the crank handle counterclockwise (CCW) to release forces and
free the adapter, drive bar, and socket.

NOTE
Torque will not be applied in a CCW direction or the fastener loosened because the ratchet is
set for CW direction operation.

5-3 USE OF A REACTION BAR:

To achieve lower torque values (up to several hundred pound-feet) or run a fastener down, the wrench
can be use like a conventional ratchet wrench when used with a reaction bar.

A. Install a socket and the wrench drive bar on a fastener as previously described.

B. Place the wrench on the reaction bar as shown in Figure 5-2 with the reaction pins fully engaged
in the holes in the reaction bar.

C. Install the reaction bar and wrench on the drive bar, and set the ratchet indexer.

D. Apply torque as you would with a conventional ratchet wrench by taking continuous small bites
until the desired torque value is obtained.

E. For higher torque values, allow the handle of the reaction bar to back up against a solid object
and apply torque using the hand crank.

5-4 POWER DRIVES:

Pneumatic or electric drives can be used as input drives for the wrench. The motors should be reversible
for right or left hand applications (tightening or loosening fasteners). Motors used with the PD 6501 must
be able to produce up to twenty-five (25) pound-feet of input torque and their recommended speeds
should not exceed 700 RPM. Motors with higher RPM, with speeds above 700 RPM will cause torque
wrench damage and should not be used. Motor drives must mate with the 1/2 inch input socket of the
wrench.

SECTION VI
MAINTENANCE

6-1 TROUBLESHOOTING:
The wrench is designed to provide maintenance-free, life-time operation when properly used in normal
machine shop or production facility environments. Misuse or subjecting wrench to dirty or damp
conditions will result in a need for repair. Table 6-1 provides a list of the most common indications of
trouble, the probable cause, and the suggested remedy.

6-2 CLEANING:
A. Clean the exteriors of the wrench after each use and before returning it to the carrying case or
storage container using a clean, lint-free cloth. After cleaning apply a light film of machine oil
(MIL-L-6085 or equivalent) to protect against corrosion.

B. When the wrench is disassembled for maintenance or there is evidence of broken parts or foreign
material contamination, wash all parts in an approved solvent (ZEP Dyna-Clean or equivalent).
Use a stiff bristled brush to clean corners, grooves, and threads. Clean small parts in a wire
basket agitating them while suspended in the cleaning solution. After cleaning allow parts to air
dry, or dry with a lint free cloth, or a dry compressed air. If parts show signs of corrosion, use a
soft wire brush or wheel to clean the surfaces. After brushing, clean parts again to ensure all dirt
and wire particles are removed.

NOTE

7
 Do not clean bearings in solvent. Wipe excess grease with a lint free rag. Visually inspect bearings
for evidence of damage or foreign material.

6-3 INSPECTION:
A. After cleaning, inspect all parts for burrs, cracks, galling, or other obvious signs of damage. Spin
bearings by hand, and listen for any sound that would indicate the presence of foreign material in
the bearing or excessive ware. Inspect gear teeth for cracking, spalling, or signs of uneven tooth
contact or wear.

NOTE
Wear limits and tolerances which aid in determining when parts should be are not critical for the
torque wrench and have been omitted from this publication.

B. Inspect screws and threaded parts for damage. Repair minor thread damage with a tap or die.
Replace any part that cannot be properly serviced. Inspect the capillary tube from the bellows to
the gauge to ensure it has not been crushed or otherwise damaged. Inspect the gauge for
damage to the pointer, shaft, or a damaged or discolored lens, replace any part that is damaged.

6-4 LUBRICATION:
A. After cleaning and inspection and prior to reassembly:

1. Pack all bearings with Mobile 28 Grease or equivalent until completely filled.

2. Lubricate O-Ring locations and meshing gears with Mobil 28.

B. Pump Mobile 28 into the assembled wrench as follows (reference Figure 6-1):

1. Pump until grease into the top grease fitting (A). Assembly is full when grease is seen
coming out of the threaded handle hole (C).

2. Repeat B.1 with lower grease fitting (B). Assembly is full when grease is seen coming
out of the hole on the front face of wrench (D).

C. See Table 6.3 for recommended and approved lubricants and sealents.

6-5 DISASSEMBLY:
6-5.1 Refer to Figure 6-3 and Parts List 8-1 and proceed as follows to disassemble the wrench. Follow good
shop practices working in a clean, dry area taking care to protect parts from contamination by dirt,
dampness or accidental loose.

NOTE
This section provides information on the complete disassembly of the wrench. If the wrench is
to be repaired by replacing a malfunctioning or damaged component, disassemble it only to
gain access to that component.

A. Remove the right handle (3) by removing socket head cap screws (4 & 5).

B. Carefully remove the torque gauge assembly (7) after removing button head cap screws (9) that
secures the gauge assembly to the housing. Remove the upper right hand hex head bolt (23) lift
off the shield (6). Loosen half dog setscrews (14), and remove socket head cap screws and
washers (10A & B) that secure the reaction adapter (8) containing the bellows (13).

8
 !CAUTION!
Self-aligning buttons (15) are held in by grease. Do not lose them when loosening setscrews
(14) and removing reaction adapter (8).
Take care not to damage the capillary tubes when removing the parts of the torque indicator
assembly.

C. Remove capillary shield (12).

D. Remove bellows and gauge assembly (13 & 7) from the reaction adapter by removing the
retaining rings (16). Disassemble the gauge assembly (7) only if it necessary to replace a
damaged lens, spacer spring or dial face.

E. Remove shims (17) from reaction adapter (8) only as necessary.

NOTE
Do not remove damaged, broken or worn reaction adapter dowel pins (11) at any time. Wrench
must be returned to the factory when replacement of dowels pins is required.

F. Remove pointer assembly (18) by stretching its spring and sliding the assembly off the ratchet
indexer (40). Replace spring if it is damaged (Item O).

G. Remove protractor (19) only if it is damaged.

NOTE
If components in the gauge assembly are to be replaced, no further disassembly is required. If
components of the ratchet or gear set assemblies require replacement, continue with Step H.

H. Disassemble bearing cover mount (20) by removing hex head bolts (21). Plastic gasket material
is used in the assembly of the bearing cover mount and it may be necessary to carefully tap the
bearing cover mount with a plastic hammer to break the seal to remove (do not use a metal
hammer).

I. Replace identification plate (1), if damaged or unreadable, by carefully punching the drive screws
(2) out from inside the bearing cover mount (20).

J. Remove screws (24) and three remaining bolts (23), then place the front of the housing face up
and lift the front of the housing off the rear housing. Gears, worms, shafts, and bearings will
remain in the rear housing section. Plastic gasket material is used in the assembly of the housing
and it may be necessary to carefully tap the housing with a plastic hammer to break the seal to
remove (do not use a metal hammer).

NOTE
When repairing the ratchet only, remove bearing (37) by lifting with two hands, then hold down
output gear (49) and lift ratchet assembly (40)and (45) out of the wrench. Proceed to Step P.
Bearing (32) should not be removed at any time by the user, the wrench must be returned to
the factory when such replacement or service is required.

K. Remove dowel pins (25) and setscrews (14) from rear housing (22) only if they require
replacement.

L. Remove input gears (26), output worms (48), bearings (29 & 30) as an assembly. Remove
retaining ring (27) to disassemble gear (26) and key (28) from the worm shaft only if necessary.

M. Remove input worm (35), races and bearings (33) as an assembly and slide off the input worm
as required.

9
 N. Lift ratchet and gear assembly with bearings cups & cones (37 & 38) and ratchet indexer (40)
attached from the rear housing section. If necessary, remove O-rings (36) from front and rear
housing sections. If O-rings are removed, replacement with new O-rings is recommended. Do
not reuse O-rings.

O. Remove retaining ring (39) to disassemble ratchet indexer (40), and carefully slide ratchet drive
shaft (45) out of the output gear shaft (46). Hold pawls (44) in closed position to avoid loosing
springs (43).

P. Output gear (49) is lightly pressed on to output gear shaft (46) and should be disassembled only
when necessary for gear replacement.

!WARNING!
Output worms (48) and output gear (49) are a matched set and must be replaced as a set, do not
mix sets.

6-6 REASSEMBLY
6-6.1 Refer to Figure 6-2 and Parts List 8-1 and to the paragraphs on Troubleshooting, Cleaning, Inspection,
and Lubrication (6-1 through 6-4) prior to reassembly of the wrench.

6-6.2 Assemble the wrench as follows:

A. Install dowel pins (25) and set screws (14) (if disassembled) in the rear housing section. Start set
screws by hand, hex head end first, from the flat side of each support, turn with an Allen Wrench
until flush with the side of each support. This leaves setscrews sufficiently loose to permit the
torque indicator assembly to be installed later.

B. Install O-rings (36) in the front and rear housing sections brushing O-ring locations with Mobil 28
Grease first (reference Figure 6-3).

C. Slide output gear (49) and bearing cups & cones (37 & 38) on the ratchet drive shaft and
carefully press them in using a suitable arbor press, if required.

D. Apply a thin film of grease to the four upright grooves used for pawls on the ratchet drive shaft
(45). Install straight compression springs (43) in the holes located in the center of the ratchet
drive shaft and install pawls (44), pawl teeth out, into each groove being careful not to disturb the
compression springs (43). While holding the pawls closed, slide the output gear shaft (46) over
and onto the ratchet drive shaft assembly.

F. With a pair of needle nose pliers, reach through the center of the output gear shaft (46) and lift
two opposing pawls (44) approximately 1/4 inch from their seats.

G. Note the locking pin position then slide the ratchet indexer (40) partially on the ratchet drive shaft
with the locking pin over the tear shaped detents on the drive shaft. Sliding the indexer on the
drive shaft until the ratchet indexer engages the seated pawls.

NOTE
It may be necessary to repeat Step F to properly engage the indexer and pawls.

H. Install retaining ring (39), secure the ratchet indexer (40) on the ratchet drive shaft (45). Hold
outer gear and turn indexer left and right to check ratchet action in each direction.

I. Install assembled ratchet drive shaft (45), output gear (49), output gear shaft (46), bearings (37),
and ratchet indexer (40) in the rear housing section.

J. Install bearing mount cover (20) temporarily with two screws (21) placed in the extreme outside
holes.

10
K. Assemble bearings (29 & 30) and gears (26), keys (28), and retaining rings (27) on output worms
(48).

NOTE
Output worms (48) and output gear (49) are a match set. They must be procured and installed
only as a match set. Alignment marks on the output gear and worms are for gears that are
being returned to the wrench. Replacement gears must be marked with Dykem or any
permanent grease proof marker (Ref. M & N). The thrust bearing (29) has one moving race.
This race must be placed toward the radial bearing (30).

L. Install output worm assembly in the housing.

M. Rotate left and right input gears (26) toward each other and adjust backlash centrally on both
gears.

N. Mark tooth and adjacent space on left-hand and right-hand input gears (26) to provide alignment
marks when installing input worm (Step O). Output worms (48) must rotate freely with no
evidence of binding before marking.

O. Assemble bearings and races (33) on input worms (35) and install the assembly in the rear
housing section so the worm meshes with the input gears (26), remove one of the output worms
assemblies slightly to make this possible. Rotate the gear train to check for proper alignment.

P. Apply sealant (Loctite No. 68 or equivalent) to the front and rear housing sections and secure the
sections together with screws (24) and bolts (23). Apply adhesive (Loctite No. 59 or equivalent)
to the threads of the screws and bolts prior to installation.

Q. Remove bearing mount cover (20), apply sealant (Loctite No. 68 or equivalent) to bottom flanges
of the housing section, reinstall the cover (20) and secure with bolts (21). Use adhesive (Loctite
No. 59 or equivalent) on the threads prior to installation.

R. Install the bellows of the bellows and gauge assembly (13) in the reaction adapter with shims (17)
and retainer rings (16). Use shims as necessary to ensure that the bellows fit snugly but not per-
loaded in the reaction adapter.

S. If protractor (19) is being replaced, install, secured when installing gauge, ref. 6-6.2.X.

T. Lubricate the wrench as required in accordance with Para. 6-4

U. Dab a small amount of grease (Mobile 28 Grease) on the dimpled portion of each bellows (top
and bottom) and gently press self-aligning buttons (15) into the dimples, curved surface to curved
surface. Grease will hold buttons in place during reassembly.

V. Install reaction adapter (8) and capillary shield (12) loosely on the rear housing section securing
with SHCS screws & washers (10A & B). Apply a thin coat of Moly-Cote to the rear of the
housing assembly with a brush (reference Figure 6-2).

NOTE
Do not seat Screws (10A) fully as the reaction adapter must be sufficiently free to rotate about
the output drive shaft during operation.

W. Remove the upper right hand bolt (23) and install shield (6). Reinstall the bolt after applying
adhesive (Loctite No. 59 or equivalent) to the threads prior to installation.

X. Install gauge (7) of bellows and gauge assembly on the front of the wrench, securing with screws
(9). Apply adhesive (Loctite No. 59 or equivalent) to the screws prior to installation. During
installation of the gauge, bend the capillary tube carefully to fit the wrench exercising caution not
to break, crush, or make sharp bends in the tube.

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 Y. Install handles (3) and screws (4) and (5). Apply adhesive (Loctite No. 59 or equivalent) to the
screws prior to installation.

Z. If ID plate (1) is replaced, install with drive screws (2).

AA. Install the pointer assembly (18) on the ratchet indexer (40) by stretching its spring and sliding
the assembly over the indexer and into the recess provided.

AB. Refer to calibration instructions (Ref. Section 6-8) for adjustment of setscrews (14).

NOTE
The wrench is always calibrated after any overhaul or any disassembly operation. It is
recommended that the wrench be calibrated at least annually.

6-7 PERFORMANCE EVALUATION

6-7.1 Prior to any wrench calibration, visually check for signs of damage to indicator gauge or capillary tubes.
Replace damaged part(s) when necessary.

6-7.2 When the wrench has been disassembled for repair or overhaul, the torque indicator assembly must be
readjusted before calibrating the wrench. Roughly re-center the arms of the torque indicator between the
extensions on the rear of the housing section by adjusting the setscrews and self-aligning buttons with an
Allen wrench until the torque indicator appears to be centered and the assembly is held firmly but with a
zero reading on the indicator gauge.

6-7.3 If the wrench has no visible signs of damage or has been repaired it is ready for calibration. Place the
wrench on a suitable calibration stand to determine if it is within specification in both the CW and CCW
directions. If the wrench is not within specification, refer to 6-8.

6-8 CALIBRATION
(Refer to Figure 6-4 and proceed as follows to calibrate the Torque Wrench.)

A. Back setscrews A through D out flush with the housing.

B. Turn setscrew A in until a slight reading is obtained on the indicator gauge; then back out
setscrew A until the indicator gauge reading returns to zero (setscrew will be just contacting the
self-alignment button).

C. Turn setscrew B in until a slight reading is obtained on the indicator gauge; then back out
setscrew B until the indicator gauge reading returns to zero (setscrew will be just contacting the
self-alignment button).

D. Back setscrew A out four (4) turns.

E. Turn setscrew B in (counting the number of turns)until a slight reading is obtained on the gauge,
then back out setscrew B 1/2 the amount of turns counted. Turn setscrew A until a slight reading
is obtained (on zero). The reaction arm is now centrally located on one side of the wrench.

F. Repeat steps B through E with setscrews C and D, starting with setscrew D. The load is now
balanced between the bellows and output drive.

NOTE
Steps A through F are performed to ensure that the torque indicator assembly is centered around the
output drive,

G. Install the wrench on the calibration stand ensuring that the drive bar and reaction pins are firmly
seated in the calibration stand reaction holes and adapter square.

12
H. Set the ratchet indexer to its full clockwise (CW) position, and apply torque to 1,000 and 2,000
lb-ft. Make note of the readings on the wrench indicator and the calibration stand, and reduce
torque to zero.

I. Set the ratchet indexer to its full counterclockwise (CCW) position, and apply torque to 1,000 and
2,000 lb-ft. Make note of the readings on the wrench indicator and the calibration stand, and
reduce torque to zero.

J. The wrench indicator readings for the CW and CCW operation should be alike within one percent
(1%) of scale reading but do not have to match the calibration stand reading (Steps H & I). If they
are not within one percent (1%), repeat Steps A through I, except adjust setscrews A and B
instead of C and D.

K. Check that the readings on the torque indicator gauge (Steps H & I) and the calibration stand
agree within two percent (2%). If they do not agree, proceed as follows:

1. Apply 1,000 lb-ft of torque as shown on the calibration stand indicator.

2. Remove the retaining ring, lens, and spring spacer from the wrench indicator.

3. Rotate the dial face to agree with the reading on the calibration stand.

4. Reinstall the spring spacer, lens, and retaining ring and repeat Steps H and I.

L. Check to ensure the torque wrench operates within the tolerances specified for both CW and
CCW operation. Make checks at seven torque settings from 1,000 lb-ft to full scale, 6,500 lb-ft in
equal increments, and record readings. Reference Table 6-2 for standard increments and
tolerances.

M. If after performing the previous steps the wrench does not balance in both the CW and CCW
directions, within tolerance, readjust setscrews as follows:

1. Back out setscrew A a quarter turn;

2. Advance setscrew B a quarter turn;

3. Re-test wrench on the calibration stand.

N. If the accuracy of the wrench has been improved by this adjustment, but is still is not within the
tolerances give in Steps I and J. back setscrew A further out while advancing setscrew B further
(the same number of turns for both setscrews). If the original adjustment has made the situation
worse, the advance setscrew A and retract setscrew B (the same number of turns for both
setscrews).

NOTE
It sometimes takes several adjustments of the setscrews before the wrench is brought into calibration.
If the wrench cannot be calibrated, gauge and bellows assembly should be replaced.

O. After calibration has been completed, seal setscrews (A, B, C, & D) and screws (10) with a
silicone sealant (Dow Corning 732 RTV or equivalent).

NOTE
Output torque, the wrench gauge reading, at any given point 1,000 FT-LBS and above is done with the
unit in a stop motion attitude. No input being applied to the crank handle.

13
 SECTION VII
PREPARATION FOR SHIPMENT OR STORAGE

7-1 GENERAL

No special provisions are required or needed for shipment or storage.

7-2 PREPARATION FOR STORAGE:

A. Short term storage (less than six months). Clean the torque wrench as described in
Section 6-2.A and return it to its carrying or storage case.

B. Long term storage (greater than six months). Clean the torque wrench as described in
Section 6-2.A and return it to its carrying or storage case. Even if the carrying or storage
case is waterproof and air tight it may be advisable to wrap the case in a suitable
moisture-proof paper for extended period storage.

7-3 PREPARATION FOR SHIPMENT:

Clean the wrench per Section 6-2.A and return it to its carrying or storage case. When returning
the wrench for calibration, repair, or modification, be sure to attach a tag to the wrench
indicating the specific problem(s) encountered during use. When possible return the drive bar
with the wrench so that its condition may also be evaluated. Package and ship using good
commercial packaging and shipping standards.

SECTION VIII
EXPLODED VIEW & PARTS LISTS

8-1 GENERAL

Figure 6-3 provides the exploded view of the PD 6501 Torque Wrench. Parts List 8-1 provides
the lists of all parts and the quantities used in the Torque Wrench. These parts are all available
from the Power-Dyne LLC, 2055 South Main Street, Middletown, CT 06457-6151, (860)343-
6640. They should be ordered by their full part number and description.

14
 PD 6501 SPECIFICATIONS
NET WEIGHT 70 LBS
SIZE (INCHES) 7 3/4 X 10 X 14 1/2 IN.
INPUT DRIVE 1/2” SQUARE
OUTPUT DRIVE BAR SIZE 1 1/2” SQUARE
RATED OUTPUT CAPACITY 0 - 6500 POUND FEET
MAXIMUM OVERLOAD CAPACITY 8000 POUND FEET
INPUT REQUIREMENTS 0 TO 25 POUND FEET
READOUT INCREMENTS 25 FT-LBS
GEAR RATIO 1350:1
OUTPUT ACCURACY (PERCENT OF SCALE
READING 1000 LB-FT TO FULL SCALE) ±2% OF READING
MAXIMUM RECOMMENDED INPUT SPEED (AIR
OR ELECTRIC MOTOR) 700 RPM
OPERATING TEMPERATURE 0° TO 150° F (-17° TO 71° C)
RECOMMENDED CALIBRATION INTERVAL 6 MONTHS

TABLE 1-1

TROUBLESHOOTING CHART
TROUBLE PROBABLE CAUSE REMEDY
1. Excessive input force (more than 1) Dirty or corroded parts 1) Disassemble, clean and
30 pound-feet) required to obtain 2) Damage or worn gears or lubricate Wrench.
maximum of 80000 ft-lbs. bearings 2) Replace faulty parts
2 Rough or erratic operation of Seized or damaged ratchet, Replace faulty parts
input crank brake, input pinion, or bearings
3. Ratchet indexer that sets the Broken pins on the ratchet pawls Replace faulty parts
ratchet mechanism won’t turn or broken ratchet pawls
4. Wrench generates torque but A leak in the hydraulic system Replace faulty parts
there is no gauge reading (bellows, gauge or tubing) or a
broken gauge mechanism
5. Wrench will not produce full Impact wrench used causing 1) Replace output gear set
output torque damage to the input square 2) Replace input worm
and/or output gear set
6. Improper output gauge reading 1) Stuck gauge mechanism 1) Free gauge mechanism
2) Wrench needs calibration 2) Calibrate wrench
7. Ratchet mechanism inoperative Ratchet pawls broken and Replace faulty parts
(wrench produces torque in both jammed or broken indexer pins
directions but will not “slip” in
either direction)
8. Improper output gauge reading Stuck gauge mechanism; or Free gauge mechanism and/or re-
wrench needs calibration calibrate Wrench
9. Wrench won’t hold applied torque Bolt is yielding or parts not fully Continue to apply torque until bolt
reading seated (tapered, rough, warped, stabilizes. If bolt continues to
etc.) yield, replace with higher strength
bolt

TABLE 6-1

15
CALIBRATION SET POINTS AND TOLERANCES ±2% & ±3%

SET POINT TOLERANCE ±2% TOLERANCE ±3%

FT-LBS PLUS MINUS PLUS MINUS
1000 1020 980 1030 970
1500 1530 1470 1545 1455
2000 2040 1980 2060 1940
2500 2550 2450 2575 2425
3000 3060 3540 3090 2910
3500 3570 3430 3605 3395
4000 4080 3920 4120 3880
4500 4590 4410 4635 4365
5000 5100 4900 5150 3850
5500 5610 5390 5665 5335
6000 6120 5880 6180 5820
6500 6630 6370 6695 6305
7000 7140 6860 7210 6790
7400 7548 7352 7622 7178
= Tolerance and Set Points used by Power-Dyne for calibration.
= Set Points and Tolerances for PD 6501 model only
= Additional Set Points and Tolerances for PD 6501-M1 model only

Table 6-2

RECOMMENDED LUBRICANTS & SEALANTS/ADHESIVES

ITEM TYPE
MOBILUX FP023 GREASE LUBRICANT
MOBIL 28 GREASE LUBRICANT
MOLY-COAT LUBRICANT
DOW CORNING 732 RTV SEALANT SEALANT
LOCTITE 222 SEALANT

Table 6-3

16
 MODEL PD 6501 POWER-DYNE TORQUE WRENCH
FIGURE 1-1

Adapter Hole Pattern & Reaction Adapter Plate Design

Three holes must be provided in every adapter to mate with the two dowel pins in the torque wrench and to
provide a clearance hole for the drive bar or shaft used to couple the torque wrench to the socket and nut. The
drawing below shows the hole pattern required for the PD 6501 torque wrench. The torque wrench must fit
loosely (1/64 to 1/32 inch clearance in the adapter and be allowed to “float” in finding a drive position with
minimum side loads on the torque wrench(ideally there should be no side loads). If the torque wrench is confined
by the adapter to one side of the nut, severe side loads will occur - and these can quickly damage the torque
wrench.

DIMENSION DIAMETER DIAMETER

“A” “B” “C”
2.500 ±.005 2 3/4” 1 1/64”

INSTALLATION OF REACTION ADAPTER

FIGURE 3-1

17
INSTALLATION OF DRIVE BAR & SOCKET INSTALLATION OF REACTION ADAPTER

FIGURE 5-1.A FIGURE 5-1.B

18
INSTALLATION OF WRENCH ON ADAPTER PLATE ROTATING THE WRENCH

FIGURE 5-1.C FIGURE 5-1.D

19
NOTE:

IF THE SQUARE HOLE IN THE OUTPUT SHAFT OF THE WRENCH DOES NOT LINE UP WITH THE
SQUARE DRIVE SHAFT, YOU CAN ROTATE THE KNURLED RATCHET INDEXER SO THAT THE
SQUARE HOLE IN THE OUTPUT SHAFT OF THE WRENCH LINES UP WITH THE DRIVE SHAFT.

TORQUE WRENCH & REACTION BAR INSTALLATION

FIGURE 5-3

20
GREASE FITTINGS & EXIT HOLES
FIGURE 6-1

21
AREA OF MOLY-COAT
FIGURE 6-2

22
23
PD 6501 TORQUE WRENCH - EXPLODED VIEW
FIGURE 6-3

24
O-RING INSTALLATION
FIGURE 6-4

25
CALIBRATION ADJUSTMENTS
FIGURE 6-4

26
 PD 6501 TORQUE WRENCH PARTS LIST
FIG. NO. PART NO. NOMENCLATURE QTY.
1 PD 110 LABEL, IDENTIFICATION 1
2 HW 201-1 SCREW, DRIVE U-TYPE #2X3/16” LG. 2
3 PD 6523 HANDLE, CARRYING (ATTACHING PARTS 4 & 5) 2
4 50-00076 SHCS, 5/16-18 X 2” LG. 2
5 50-00069 SHCS, 5/16-18 X 5/8” LG. 2
6 PD 2598 SHIELD, CAPILLARY 1
7 PD 6504 BELLOWS & GAUGE ASS’Y ⌦1 (REF. ITEMS A to G) 1
8 PD 6522 ADAPTER, REACTION (ATTACHING PARTS 10A & 10B) 1
9 50-00762 BHCS 1/4-20 X 3/4” LG 2
10A 50-00049-02 SHCS 10-24 X 1 1/4” LG W/NYLOK 4
10B MS 27183-4 WASHER 4
11 50-00940 DOWEL PIN, 3/4”∅ X 2 1/2” LG (REACTION PINS) 2
12 PD 6521-1, -2 SHIELD (R.H. -1, L.H. -2) 1@
13 PD 6504-1 BELLOWS ASSEMBLY 1
14 50-00591-02 HALF DOG SS 1/2-13 X 1 1/2” LG 4
15 PD 6536 BUTTON, SELF ALIGNING 4
16 HW 505-53 RING, RETAINING 2
17 PD 10-17- SHIM (-02, -03, -10 SELECTED AT ASS’Y) A/R
18 PD 6528 POINTER ASSEMBLY W/PD 18-3 SPRING 1
19 PD 6529 PROTRACTOR 1
20 PD 6512 COVER, BEARING MOUNT 1
21 50-00815 HEX HD BOLT, 5/16-18 X 1” LG 16
22 PD 6511 HOUSING (PD 6511-1 & -2 REF.) 1
23 50-00816-02 HEX HD BOLT, 3/8-16 X 1 3/4” LG 4
24 50-00076 SHCS, 5/16-18 X 2” LG 4
25 50-00869 DOWEL PIN, 3/16”∅ X 7/8” LG 2
26 PD 6541 GEAR, INPUT 2
27 HW 505-22 RETAINING RING 2
28 50-00964 KEY, 3/8” SQ. X 1” LG 2
29 PD 9-3 BEARING, THRUST 4
30 PD 8-3 BEARING, RADIAL 4

32 PD 6-2 BEARING, NEEDLE 2

33 & 34 PD 9-5 BEARING, THRUST, WASHER & BEARING 2
35 PD 6524 GEAR, INPUT WORM 1
36 HW 508-45 O-RING 2
37 & 38 PD 7-1 SINGLE ROW BEARING, TYPE TS, CONE & CUP 2
39 HW 505-47 RETAINING RING 1
40 PD 6525 INDEXER, RATCHET 1
41 PD 5-11 PIN, LOCKING 1
42 PD 17-4 SPRING, COMPRESSION 1
43 C0240-026-0620M SPRING, PAWL 4
44 PD 6519-1, -2 PAWL, RATCHET 2@
45 PD 6521 RATCHET DRIVE 1
46 PD 6520 SHAFT, OUTPUT GEAR 1
47 PD 6506 GEAR, OUTPUT SET (MATCHED SET (REF. 48 & 49) ⌦2 1
48 WORM, OUTPUT (PART OF PD 6506)
49 GEAR, OUTPUT (PART OF PD 6506)
50 PD 6507 DRIVE BAR ASSEMBLY 1
51 PD 20015 TORQUE CRANK ASSEMBLY 1
52 PD 6551 CASE, CARRYING 1

PARTS LIST 8-1

27
 PD 6501 TORQUE WRENCH PARTS LIST (CONT’D)
FIG. NO. PART NO. NOMENCLATURE QTY.
PARTS NOT SHOWN IN EXPLODED VIEW
A 1U-316 UNION ⌦1 1
B PD 6535- DIAL FACE (-1, -2, -3, -4, -9) ⌦1 A/R
C PD 636 GAUGE, MODULE, 3000 PSI ⌦1 1
D PD 126-3 POINTER, PRESSURE GAUGE 1
E PD 6524 GAUGE HOUSING ⌦1 1
F PD 6515 LENS ⌦1 1
G PD 6517 SPACER SPRING ⌦1 1
H HW 505-50 RETAINING RING (RR-200 SS) ⌦1 1
I HW 505-50 RETAINING RING (RR-200 SS) ⌦1 1
J HW 503-2 GREASE FITTING (1/4-28) 2
K PD 10-17-XX (-02, -03, -05) SHIM (UNDER PD 9-3, ITEM #29) A/R
N PD 10-20-XX SHIM (-02, -03, -10) (UNDER PD 7-1, ITEMS 37 & 38) A/R

NOTES:
⌦1 = PART OF ITEM #7, PD 1255-1, GAUGE ASSEMBLY. MAY BE ORDERED AS AN ASSEMBLY OR AS
PIECE PARTS. THE FOLLOWING ASSEMBLIES MUST BE ORDERED AND REPLACED AS SETS:
A) LENS (E) AND SPACER SPRING (F);
B) GAUGE (C), POINTER (D), AND UNION (A) MUST BE REPLACED AS A SET.

⌦2 = OUTPUT GEAR SET (47) THESE MUST BE REPLACED AS A MATCHED SET.

PARTS LIST 8-1

28