Calibration Procedure of the A.K.O. Hydraulic Dynamometer

TECHNICAL PROCEDURES

Calibration Procedure of the A.K.O. hydraulic dynamometer

1. Subject of the Procedure

This procedure describes the calibration procedure for the RT Tools and RT ratchets on the A.K.O. Hydraulic dynamometer.

2. Description of the Procedure

 Safety Measure

Risk(s): High-Pressure hydraulic oil leak

Prevention: Wearing Safety glasses compulsory Wearing Safety shoes compulsory Limit access to the area of work to the person(s) in charge of performing the test.

PREPARATION Ensure that the A.K.O. Torque Master Computer (key/locked cabinet) is connected to the LAN and able to access LAN Printers. Ensure that your hands are clean and dry, free of oil, grime or debris. Ensure the RT wrench/ratchet tool to be tested/calibrated is dry and clean. Consult with your supervisor if you observe a leaky tool, a damaged fitting or ratchet, or other tool anomaly. Gather the paperwork for the tool. This may include the Sales order and/or the Work order. Ensure the tool model number and serial number on the label on the tool matches the same numbers on the paper work. Ensure the four knob hand crank piston on the TSD 6500 is backed out to the zero position (turn counter-clockwise), till you reach the soft ‘stop.’ Do not apply pressure any stronger than a ‘finger-touch’ as you turn (rotating counterclockwise) the hand crank lower than 300 psi to reach the soft ‘stop.’ Too much pressure might damage the crank bushings or o-rings.

PRT111-01 version 4 Page 1 of 17 Date of Approval 10/06/2009 TECHNICAL PROCEDURES

STEP #1 -- Reserve a Certificate number for the tool

1) Place RT tool on the calibration bench with its Sales order or its Work order and ensure customer name, tool type and serial number match on tool and on paperwork.

2) Get spiral bound tracking notebook and transcribe tool name and serial number from the tool and the customer name from either the sales order or the work order.

3) Go to the A.K.O. Torque Master computer and ensure it is ‘powered-on’ and the typical desktop is displayed on the computer monitor. Ensure the computer is connected to the LAN. Operator may have to unlock the cabinet and re-connect the RJ45 LAN cable and then “boot” the computer before proceeding. The start button, or “boot” button of the computer will light-up when it is pushed to ‘power-on’ the computer.

4) Locate and then double click the “Calibration folder.” Then locate and double click on the MS Excel file named “Calibration Number Book.”

5) Select the correct “tab” of the excel worksheet for the RT tool you are calibrating/testing. Click once on the tab and then look for the ‘next open’ row or blank row in the data table that appears.

6) Calculate and then type in the ‘next’ integer based certificate number. (The formula for calculating the next certificate number is to add 1 to the value column “A” of the prior row. E.g… C-10504 plus 1 = C-10505).

7) The new Certificate number begins with a “capitalized C” and then the next sequential integer. This number is entered in column “A”.

8) Type in the following corresponding data in columns “B,” “C,” and “D” – e.g. type the following": Column B: today’s date (mm/dd/yyyy); Column C: Customer Name, and, Column D: the Tool name and its Serial number.

9) Locate the icon and then “click save” to capture and store the data in the spreadsheet. Verify that the data you typed in is correct and matches the Tool and its Paperwork.

10) Transcribe the newly assigned Certificate number into the spiral bound notebook.

11) Close the excel spreadsheet.

STEP #2 -- Load the tool on the testing/calibration mandrel

1) Place the RT tool on the calibration bench.

2) Compare the wrench/ratchet tool size to the mandrel size in place on the A.K.O. Torque Master and, if required, switch out the mandrel to ensure correct fit and test. (The mandrels are stored in the locked cabinet of the A.K.O. Torque Master TSD40035-HT Calibration Unit; below its pressure plate.)

3) Ensure both the mandrel and tool are clean and place the tool on the mandrel so that the square drive of the tool is on your right as you look down on the tool.

4) Make sure that the reaction arm boot of the tool is parallel with the large reaction plate of the machine (use steel plates to adjust the reaction block---see example below).

GOOD NOT GOOD

5) Connect the twin hydraulic lines to the tool/wrench. Tighten the couplings “finger-tight” firmly; yet, do not use a tool to tighten the lines.

6) Double-check that the couplings and the lines are clean and dry. Double-check that the tool is firmly placed on the right-sized mandrel and that it and the reaction plate guard are clean and dry.

STEP #3 – Initialize the certificate label data and environmental factors

1) Go to the computer desktop. Double click on the icon “Torqcal2000” to open the Calibration software.

2) Type in your name in the “Operator ID” data field. This data field is in the lower left side of the active window. Enter the first letter of your first name and your entire last name in capitals; for example: “J. RAMIREZ” –or-- “R. HALE”

3) Look down to the list of tools in the scroll-window box named “Templates” located on the right bottom corner of the screen. Use the scroll bar to locate the name of the tool you wish to test/calibrate. Double click on the tool name to open its unique customer data sheet. (the data sheet will then open automatically) Then type in data for ONLY the following data fields with information requested (Data from the Sales Order or the Work Order):

- Customer name - Customer address - City/State/Zip - Country

4) Look up at the sensor on the wall, at the Tesco 175-HT humidity and temperature digital sensor. Read the temperature and press the mode button on the device to read the humidity. Ensure the temperature and humidity are within acceptable calibration ranges. (See the specs. On the lab binder). Type in data for ONLY the following data fields with information requested:

- Temperature (degrees Celsius) Example: for degrees Celsius, you will see “26.3” - Do not enter ‘tenths’ or the “o” key. Type in only an integer; for example: 26.

- Humidity – Example: you will see “32.3” - Do not enter ‘tenths’ or the “%” key. Type in only an integer; for example: 32.

5) Calculate the date for the next scheduled calibration. The formula for the “Next Cal Date” = Calibration date + one year – one day. Example: 06/04/2008 is the day of calibration - Next Cal Date will be 06/03/2009.

6) Enter the next calibration date in dd/mm/yyyy format. Continue to enter the following data from either the Sales order or the Work order.

** Tool ID/SN = the serial number

Example: RT10 S/N 2310 Write Tool ID/SN= 2310

7) Move the mouse over to the lower right corner of the active window to click the “Done” button once. The customer data sheet closes automatically.

8) Go to “File” on left top of the “Torqcal2000” and click “Save” – The window “Save as” will pop up to become the top page on the monitor. (else look for a blinking ICON at the base of the screen)

9) Next, in the “save as” window, you double click the type of tool being calibrated and clear-out the serial number. You name the file to be saved using the following pattern: “tool name-Serial Number- Company Name”.cdw. An RTX tool file name might look like: “RTX-2-1234- Company.cdw”. Next, if your file name typing matches the abbreviated data from the Sales order or the Work order, then, you press “finish.” Otherwise, make the necessary corrections and press “finish.”

10) A new dialogue box will open automatically. In it, you press on the Save icon.

STEP #4 – Initialize the TSD 6500 hydraulic pressure dynamometer

1) Turn on the A.K.O. -- TSD 6500 by locating the calibration display (see below), and then switch the black power button located on the bottom right corner to the “1” –or- ‘on’ position.

2) Two display windows will appear in the LCD Screen:

- The upper display will show the pressure (10,000 psi max).

- The lower display will show you the torque (40,000 ft. lb max).

- Make sure the values on the displays are at zero before starting the calibration. If they aren’t at zero, push the zero button on the screen and select display-1. The value will change to zero. Repeat the same thing for display-2.

3) Turn on the A.K.O. Hydraulic pump. This is a two-step process. First, the operator flips the ‘nickel-plated’ toggle switch to the “ON” position; and then, the operator pushes the green start button.

4) Keep your hands off the tool being tested, the one loaded on the A.K.O. mandrel.

5) Move the clutch lever (see picture on the left) of the pump unit from neutral to advance. The tool (if loaded properly on the mandrel) will be slowly rotated to put its reaction arm boot against the large reaction block. While grasping the clutch lever, watch the tool as it rotates and listen for the tool ratchet to ‘click’. The pressure and torque will slightly increase on the calibration display. This is normal.

6) Move over to the mandrel and check the tool and the hydraulic lines. Is the reaction boot of the tool positioned correctly against the reaction block? (see above, Step #2 – 3 & 4). Is the tool firm and immobile? Are the pressure lines still finger tight and still dry? If you answer “no” to any of these check observations, immediately place the clutch lever in neutral and then move the lever up to retract for a moment, to reposition the tool. Ensure the pressure lines are finger tight and dry. Repeat steps 4 through 6 as required to initialize the tool for proper testing.

7) Once all check observations prove safe, and all is tight and dry, then, ensure you are wearing safety glasses and move the clutch lever to neutral.

PERFORM CALIBRATION

STEP #5 – Begin the first series of pressure tests

1) Go back to the computer screen. Press the “start test” button. A smaller dialogue box or window titled: “Manual control box” will appear. Use the mouse to move this smaller window to the right side of the monitor screen (see screen shot below).

2) Grasp the clutch lever on the pump control, and move it from Neutral to Advance. Look at the Torqcal2000 screen and make sure the “test menu top indicator button” on the right side of the TORQcal2000 screen reads: “Running.” (In the illustration, the indicator button is just above ‘right center’ of the screen shot and just below and to the left of the “blue” “Manual Control” screen bar.)

3) Use the mouse to place your cursor on primary window RESULT 1 and click the “LEFT” mouse button once. (Primary window RESULT 1 is located in the lower part of the Torqcal2000 window).

4) Now you can start the calibration tests for the tool. The machine takes first measurement at 1,500 psi then 2,000 psi and after every 1,000 psi above 2,000 psi up to 10,000 psi.

STEP #6 – Activate the pump pressure and perform tests

1) Move the clutch lever on the pump from Neutral to Advance.

2) Turn the 10,000 psi regulating valve (a four knob valve wheel) located on the pump unit, slowly, clockwise. Now, check that the pressure increases. Rotate the valve slowly to increase the pressure above 100 psi.

Clockwise rotation increases pressure; counter-clockwise rotation decreases pressure.

3) After the pressure value on the computer screen reaches 200 psi, stop rotating the hand crank regulating valve and go to the A.K.O. mandrel and tool. Check that both pressure lines are still dry and clean and finger-tight.

4) If the lines or couplings are wet or leaking, immediately relieve the pressure in the system. Go to steps 12-15 of this section (Step #6). Quickly follow the instructions to relieve system pressure. Now, go back to major Step #2 and begin again to reset the lines or the tool as required.

5) However, if your observations show all is still dry and tight at the Mandrel, then, go back to the A.K.O. pump hand crank regulating valve.

6) Continue rotating the valve clockwise to increase pressure to about 1,500 psi, the first recorded reading. Eventually, the operator will rotate the valve to advance pressure to 2000, 3000, 4000, etc… As you turn, you build up the pressure and at the same time the calibration unit detects the torque dynamically in real-time. The unit will capture pressure readings every 1,000 psi (Pressure can be checked at any moment on the calibration display and on the computer screen) for your calibration tests.

The torque value is automatically transferred to the computer screen.

WARNING

If at any thousand psi measuring interval (e.g… the table values) there is no torque/psi value transferred to the computer screen, then, that means you have rotated the valve too fast. Slow down and continue the calibration tests.

7) Watch the pressure value in the software screen. Continue to apply pressure to turn the hand crank clockwise so that the value increases to the desired (or new calibration step-pressure psi value) pressure. Slowly turn the hand crank as you approach the desired pressure. As you observe the pressure value reach the desired number/threshold in the pressure table, you will pay attention, and listen for a “ping/beep” from the computer. This sound will notify you that the software has registered the actual desired calibration step-pressure psi value.

8) Once the value is recorded, the software automatically moves to the next test-value (from top to bottom) in the table.

Note: When the pressure exerted on the tool reaches the exact desired pressure in the system table; look back at the monitor and continue to listen for a “ping/beep” sound. The operator may have to slightly decrease or increase the pressure on the tool by carefully turning the hand crank a very small portion of a rotation. It is recommended to use both hands to make these slight adjustments to valve hand crank. The operator should keep their hands off the tool being tested and must watch the system psi read-out carefully as it approaches the exact desired table test-value. The operator may observe that the

pressure indicator value goes just beyond the desired psi mark in the system table during these adjustments. That is normal.

9) After the software makes the ‘sound,’ it has recorded the calibration measurement. The operator should stop turning the hand crank and look back at the computer monitor. The TORQCal-2000 program window should now show recorded values in the table row for which the operator was calibrating.

Once the 10,000 psi limit is reached and you have a torque value for it, a new window will open with the following words in RED: “Test complete”.

10) Push the “Done” button in the “Test complete” window. Begin to turn back (rotate counter- clockwise) the four-knob pressure regulation valve. Keep rotating it counter-clockwise till it becomes much easier to rotate. Carefully and slowly rotate the valve back down to ‘zero’ psi.

11) Next, place your cursor on the primary window RESULT 2 and click once. Push the Start Test button again and repeat the process five times. (You will repeat steps 2-6 for the five series of tests required to calibrate the tool.) You will advance from Result 1 to Result 2 to Result 3 until you successfully reach Result 5.

NOTE: this screen shot shows we are working on the “8,000 psi” test reading for Result #2 on an RT-5 tool.

12) When the five tests are completed, shift the clutch lever on the pump to Neutral. Next move the lever to retract. Watch the tool rotate off the guard.

13) Turn the pump unit off. Press the Red “Stop” button and flip the toggle switch to the off position.

14) Now, move the clutch lever from Neutral to Advance, back to Neutral and next, to Retract, then, back to Neutral. Do this twice (meaning two full times in sequence). Listen for the ‘puff’ sound of the pressure release valve.

15) Move over to the A.K.O. mandrel and check the pressure lines. Ensure the lines are not under pressure and are flexible and limp. Unfasten or rotate one line off the tool coupling.

16) Now, press the “done” button on the active screen of the computer monitor.

17) Click save on the Torqcal2000 window. The save-as window will pop-up. Double click on the type of wrench you just tested/calibrated.

18) Click once on your certificate# and customer name then click save.

STEP #7 – Check the results of the Tool Calibration and Tests

1) Click “Result” button on the Torqcal2000 window in the “Test Menu”. A new dialogue window will open automatically.

2) Click on CAL-US, CAL-FR or CAL-DE depending on the customer, with the cursor to open CAL-US, CAL-FR or CAL-DE. PS – For RT-50, use the specific template CAL-US_50.

3) An “Excel page” will open with the 2 “certificate of calibration” pages.

4) If necessary, change the Certificate # in the Excel “Column&Row” box B-6 with the number reserved on step #2 (Calibration Number).

5) Double-Check the following information on the first page:

Customer’s name & address - Model - S/N – Temperature –Humidity - Operator

Make sure that everything corresponds with what you entered on the customer data sheet during Step #3. If necessary, type in the correct data and enter the correct operator and supervisor names based on which person conducted the calibration.

6) Locate the tab for the second page of the spreadsheet at the bottom of the computer monitor, and click once on it.

7) Check the second page for accuracy on: -The Date of calibration (H6) & Valid Until (H7) -Make sure every “average pressure value” cell in the pressure torque table is GREEN. -If any cells are high-lighted RED, prepare to re-initialize the tool and perform the test/calibration again.

8) Locate the ‘save’ icon on the spreadsheet and press it to save the data.

9) If all the results are good and there are no “red-highlighted values” then, proceed to STEP #9 Create Certificate. If not, and there are some ‘bad’ data results and are some “red” cell values, then, proceed to STEP #8 -- Re-initialize the tool and Re-Calibrate.

STEP #8 – Re-Initialize the Tool and Re-Calibrate

1) Ensure the A.K.O. Pump is off and the clutch is in the Neutral position, and, that the TSD 6500 display reads zero or close to zero psi.

2) Go to the mandrel and ensure the hydraulic lines are limp, not under pressure. Disconnect both hoses from the RT tool. Place the two hose ends in the drain box. Wipe the tool down and manually rotate the chuck ratchet.

3) Take the tool to the re-work bench to ensure the ratchet moves freely under normal operation.

4) Place the tool on the re-work bench. Use pliers as required, and remove the ratchet pin.

5) Manually rotate the ratchet sleeve a few positions (clicks) and re-insert the pin.

6) Connect the tool to the Shop pump hoses. Make hose coupling connections finger tight. Do not use a wrench.

7) Power-up the electric shop pump and increase pressure with the hand-held remote control. Cause the tool to make a single ‘click’ –as the ratchet sleeve/chuck rotates.

8) Increase pressure slightly 10 to 12 more times with the remote control and trigger the tool to ‘click’ each time.

9) Reduce the shop pump pressure to zero. Power-down the pump. Press the pressure relief valve twice to make sure there is no hose line pressure.

10) Disconnect the tool from the hoses.

11) Wipe down the tool with a clean shop rag; ensure no debris gets on or in the coupling sleeves.

12) Take the tool back to the calibration lab.

13) Begin the calibration process again and return to: “STEP #2 -- Load the tool on the testing/calibration mandrel” of this check method procedure.

Note: if the tests prove bad again, report the results immediately to your supervisor.

STEP #9 – Create the Calibration Certificate

1) When everything is checked, click the MS office button located on the left corner of the screen then select Print ,

2) In “printer name” choose PDF creator

3) In “print range” select “ from: 1 to 2”

4) In “print what” select: entire workbook.

5) Click OK at the bottom right. A window PDF creator 0.9.3 will open.

6) Change “document title” to the correct certificate# and customer name (step 3, #6) for the tool that just passed calibration. Then, after ensure the tool, S/N, customer name and all other data is correct, locate the save icon, and click once on “save.”

7) A new “save-as window” will pop-up on the monitor. Now, click save again.

8) When PDF is on the screen, click on “File”, select “Print”, in page Handling select copies “2”, press OK - the window close automatically. The printed file is “cert#-Customername.

9) Close the PDF File – Close the Excel File. Don’t save changes to the Excel file.

10) The original Certificate and the copy both need to be checked by the operator and signed by the operator and the shop supervisor.

11) The two pages of the original certificate should be laminated recto-verso – making them durable and more smudge or tear-proof.

12) The operator will file the copy of the calibration certificate in the Calibration Lab file cabinet. The original certificate, now laminated, will be moved with its tool to the Work-in-process shelf in Shipping Receiving, (or, in the rentals inventory are as appropriate). The certificate copy is filed by customer name by date by tool-type.

STEP #10 – Create the tool’s Calibration ‘label’

1) Move to the computer linked to the adhesive label maker. Find the “label-Mark-Plus” icon on the computers desktop.

2) Double-click the short-cut icon for the “Label-Mark-Plus”.

3) Ensure the Labeling unit is powered “on.”

4) Now, in the new dialogue window, look for the folder named; “Saved File.”

5) Double click on the “Saved File.” Look for the file named; “Calibration.lpf”

6) Double click on the icon or file named “Calibration.lpf.”

7) Type in the data fields. First, key in the Tool or Gage name; then press tab.

8) Type in the Certificate number from the printed certificate. Type in the serial number of the tool or Gauge. Type in the calibration “Valid-till” date. Enter the date in mm/dd/yyyy format. The correct date is one day less than a full year from today’s date; or, equals today’s date + 365 calendar days – one day.

9) Press the ‘print button” with the mouse cursor.

10) A new ‘print dialogue’ window will open, usually in the center of the monitor screen. Locate the number of copies to print (in the ‘copies/count’ data field) on this window. Ensure that you correct the ‘count’ so that you print only one label (e.g…. count = 1). Next, press the “OK” or the “print” button in the lower right corner of this window once.

11) Retrieve the new label from the “Label-Mark-Plus.” Put the label on the certified/calibrated part-tool-gauge. Close out the “Label-Mark-Plus” software application, unless you need to create other labels.

12) Gather the part-tool-gauge and the laminated certificate and place them on the “In-Process” storage rack in the shop. ----End of Proceedure---

PRT111-01 version 4 Page 17 of 17 Date of Approval 10/06/2009