Enerpac HMT Series User manual

Document Number: L4478
Document Revision: A
Document Revision Date: 25-AUG-2020
Document Language: ENGLISH EN
Operation and Maintenance Manual
HMT Modular Tool
Enerpac HMT
To reduce the risk of injury, user must read and understand this document before use.

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ABOUT US
Enerpac is a global market leader in high pressure
hydraulic tools, controlled force products, portable
machining, on-site services and solutions for precise
positioning of heavy loads. As a leading innovator with a
110-year legacy, Enerpac has helped move and maintain
some of the largest structures on earth. When safety and
precision matters, elite professionals in industries such as
aerospace, infrastructure, manufacturing, mining, oil & gas
and power generation rely on Enerpac for quality tools,
services and solutions. For additional information, visit
www.enerpac.com.
WARRANTY
Refer to the Enerpac Global Warranty document for terms and conditions of the product warranty. Such warranty
information can be found at www.enerpac.com.
NAMEPLATE
AVAILABLE LANGUAGES
L4478 is available in the following languages, visit www.enerpac.com for a copy.
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Tool
Name
Tool
Number
Location of Manufacture ATEX Rating
Compliance Marking
Warning Alert
Read Owner Manual Symbol Pinch Point
Warning
3D
Barcode
Tool Serial Number
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Contents
1. SAFETY.......................................................................................................................................................... 3
1.1 SAFETY PRECAUTIONS ...................................................................................................................... 3
1.2 ATEX SAFETY PRECAUTIONS............................................................................................................. 5
2. COMPLIANCE STATEMENT(S) .................................................................................................................... 6
2.1 EU DECLARATION OF INCORPORATION ........................................................................................ 6
2.2 ATEX COMPLIANCE STATEMENT....................................................................................................... 6
3. FEATURES & COMPONENTS ...................................................................................................................... 7
3.1 FEATURE DIAGRAM ............................................................................................................................. 7
3.2 FEATURE DESCRIPTION...................................................................................................................... 9
3.3 HOSE CONNECTION .......................................................................................................................... 11
4. TECHNICAL PRODUCT DATA.................................................................................................................... 12
4.1 HMT WITH HLP CASSETTE DIMENSIONAL CALLOUT ART........................................................... 12
4.2 HMT WITH HLP CASSETTE DIMENSIONAL TABLE.........................................................................12
4.3 HMT WITH HSQ CASSETTE DIMENSIONAL CALLOUT ART .......................................................... 13
4.4 HMT WITH HSQ CASSETTE DIMENSIONAL TABLE........................................................................ 13
5. OPERATION................................................................................................................................................. 14
5.1 INITIAL SETUP .................................................................................................................................... 14
5.2 OPERATING HMT WITH HLP CASSETTE ASSEMBLY ..................................................................... 15
5.3 OPERATING HMT WITH HSQ CASSETTE ASSEMBLY..................................................................... 16
6. STORAGE .................................................................................................................................................... 16
6.1 RECOMMENDED STORAGE .............................................................................................................. 16
7. MAINTENANCE........................................................................................................................................... 17
7.1 GENERAL MAINTENANCE................................................................................................................. 17
7.2 PREVENTATIVE MAINTENANCE ...................................................................................................... 17
7.3 FULL MAINTENANCE......................................................................................................................... 17
8. PARTS LIST ................................................................................................................................................. 24
9. TROUBLESHOOTING ................................................................................................................................. 38

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1. Safety
1.1 Safety Precautions
Failure to observe and comply with the following
precautions could result in death or serious personal
injury. Property damage could also occur.
• Always wear protective head-wear, ear protectors,
footwear and gloves (at a minimum rigger type
gloves) suitable for safe operation of the tool.
The protective clothing must not interfere with
safe operation of the tool or restrict the ability to
communicate with co-workers.
• Be sure your workplace is safe. Follow the
instructions in your workplace’s standard
operating procedures and be sure to observe all
communicated safety precautions.
• Do not place any part of the body between the
wrench reaction foot and the reaction point.
• Do not place any objects between the wrench
reaction foot and the reaction point. Keep the
hoses away from the reaction points.
• Do not stand in the line of movement of the tool
when it is in operation. If the tool separates from
the nut or bolt during operation it will detach in that
direction.
• Be aware that a nut or bolt that breaks off during
operation of the tool may become a high velocity
projectile.
• Be sure appropriate guards are securely in position
and free from damage.
• Keep your hands away from the fastener being
loosened or tightened. Tightening and loosening
nuts and bolts involves little visible movement.
However, the pressures and loads are extreme.
• Maximum allowable operating pressure for the
HMT-Series torque wrench is 10,000 psi [690 bar].
Do not exceed this pressure setting.
• Always be sure that pump is stopped and
all pressure is fully relieved (0 psi/bar) before
disconnecting or connecting hydraulic hoses. The
sudden and uncontrolled release of pressurized oil
could occur if hoses are disconnected while under
pressure.
• Never attempt to connect or disconnect hoses while
the pump is on and/or the system is pressurized.
• Be certain that all hose couplings are fully
connected at both the pump and wrench ends
before applying any hydraulic pressure. If the
couplings are not fully connected, oil flow will be
blocked, and the wrench could be subjected to
excessive hydraulic pressures. Catastrophic failure
of wrench could result.
WARNING
Read all instructions carefully. Follow all recommended
safety precautions to avoid personal injury as well
as damage to the product and / or damage to other
property. Enerpac cannot be responsible for any
damage or injury from unsafe use, lack of maintenance,
or incorrect operation. Do not remove warning labels,
tags, or decals. In the event that any questions or
concerns arise, contact Enerpac or a local Enerpac
distributor for clarification.
Save these instructions for future use.
If you have never been trained on high-pressure
hydraulic safety, consult your distributor or service
center for information about Enerpac Hydraulic Safety
Courses.
This manual follows a system of safety alert symbols,
signals, words, and safety messages to warn the user of
specific hazards. Failure to comply with these warnings
could result in death or serious personal injury, as well
as damage to the equipment or other property.
The Safety Alert Symbol appears throughout
this manual. It is used to alert you to potential
physical injury hazards. Pay close attention
to Safety Alert Symbols and obey all safety
messages that follow this symbol to avoid the possibility
of death or serious injury.
Safety Alert Symbols are used in conjunction with certain
Signal Words that call attention to safety messages or
property damage messages and designate a degree or
level of hazard seriousness. The Signal Words used in
this manual are DANGER, WARNING, CAUTION, and
NOTICE.
Indicates a hazardous situation that, if not
avoided, will result in death or serious personal injury.
Indicates a hazardous situation that, if not
avoided, could result in death or serious personal injury.
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate personal
injury.
Indicates information considered
important, but not hazard related (e.g. messages related
to property damage). Please note that the Safety Alert
Symbol will not be used with the signal word.
DANGER
WARNING
CAUTION
NOTICE

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• Never apply more hydraulic pressure to any tool,
hose, fitting or accessory than the maximum
allowable pressure as stated in the manufacturer’s
specifications. The system operating pressure
must not exceed the pressure rating of the lowest
rated component in the system.
• Be sure the operator has completed safety induction
training, specific to the work surroundings. The
operator should be thoroughly familiar with the
controls and the proper use of the tool.
• The operator must be of at least the minimum age
required by applicable local regulations, laws and
the facility standard operating procedures.
• Do not abuse or overstress the hoses in any way.
Do not bend the hoses excessively.
• Take every precaution to prevent oil leaks from
occurring. High pressure oil leaks can penetrate
the skin, resulting in serious injury.
• Never strike the tool while it is pressurized or under
load. Components under tension may become
dislodged, allowing them to become dangerous
projectiles. Uncontrolled release of pressurized
hydraulic oil could also occur.
• Avoid striking the tool at any time, even when it
is not pressurized or under load. Striking the
tool could cause permanent damage to wrench
components and may affect the wrench calibration.
• Use only a high quality non-flammable solvent for
cleaning and degreasing parts during wrench repair
procedures. To reduce the risk of fire or explosion,
do not use flammable solvents.
• Be sure to wear proper eye and hand protection
when using solvent. Always follow the solvent
manufacturer’s safety and use instructions and
any additional instructions included in the standard
operating procedures for your work-site. Be certain
there is adequate ventilation when using solvent.
Failure to observe and comply with the following
precautions could result in minor or moderate
personal injury. Property damage could also occur.
• Always carry the wrench by its housing. Never
carry the wrench using the positioning handle. The
handle could break and the wrench could drop
suddenly. The positioning handle is designed only
as an aid to help position the wrench on the bolt
or nut.
• Be sure that backup wrench (on the opposite
end of nut or bolt being tightened or loosened) is
secured so it cannot drop or become disengaged
during bolting procedures.
• Be sure that the hex socket size corresponds to the
size of the fastener being loosened or tightened.
Failure to observe this precaution can result in
the wrench becoming unstable and can lead to
catastrophic failure of the tool.
CAUTION
• Always position the wrench for maximum stability.
Use the positioning handle to properly position tool
during operation.
• Be sure reaction points are adequate for the forces
at work during operation of the tool.
• Be sure the reaction point is of a suitable shape. If
possible, use an adjacent nut or bolt as a reaction
point.
• When the hex socket is placed on the nut or bolt
a gap may exist between the reaction foot and
the reaction point. When the tool is operated the
reaction foot and point will make forceful contact.
Be sure the wrench is stable before applying
hydraulic pressure.
• Provide adequate support in vertical and inverted
applications.
• The torque required to loosen a nut is variable and
may exceed the torque capacity of the wrench.
Never operate the wrench at above 75 percent of
its rated maximum torque when loosening a nut or
bolt.
• Be sure to minimize torsional and bending stresses
in the wrench, the hex socket and any accessories.
• Bolt lubricants and anti-seize compounds will have
a rated coefficient of friction. Be sure to know the
coefficient of friction for the lubricant or anti-seize
compound that is being used. To ensure proper
tightening of nuts and bolts, always use this
coefficient of friction when calculating required
torque values.
Failure to observe and comply with the following
precautions could result in property damage and/or
void the product warranty.
• Never carry the wrench by its hoses.
• Always use Enerpac pumps and hoses.
• Always use Enerpac replacement parts.
• The maximum torque output of the wrench must
always exceed the torque required to loosen or
tighten the nut or bolt.
• Never operate the wrench with a hydraulic supply
connection to the advance side only as this may
damage the internal parts.
• In severe service conditions, be aware that the
wrench must be inspected, cleaned and lubricated
more frequently than normal.
• Check that the swivel post screws are tight prior
to use.
• If oil leakage is present from wrench, replace seals
as required before placing the wrench back into
service.
• If the wrench is dropped from a significant height,
have the tool inspected and checked for proper
operation before placing it back into service.
• Always follow the inspection and maintenance
instructions contained in this manual. Perform
maintenance and inspection activities at the
specified time intervals.
NOTICE

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1.2 ATEX Safety Precautions
Reducing the Risk of Explosion
Failure to observe and comply with the following
precautions and instructions could result in
explosion and/or fire. Death and/or serious personal
injury could occur.
• To help reduce the risk of explosion, be certain
to use the HMT-Series torque wrench only in the
specific explosive atmospheres for which it has
been tested and certified. Refer to the beginning
of this section for ATEX classification information.
• The HMT-Series torque wrench is generally not
considered as a potential source of ignition.
However, proper operation and maintenance of
the tool is essential in order to help ensure that no
sparks are generated that could cause an ignition
of an explosive gas or dust mixture (which might be
present in the environment). Complete operation
and maintenance instructions must be provided to
all personnel in advance of operating or servicing
the wrench.
• Hot surfaces can be a major source of ignition.
To help prevent the possibility of ignition resulting
from excessive surface temperatures, do not use
the wrench in an environment with an ambient
temperature of above 104°F [40°C].
• Enerpac has designed and constructed the HMT-
Series torque wrench to minimize the possibility
of an incendiary spark that may be caused by the
impact of aluminium components with corroded
steel. However, to reduce the chance of an
incendiary spark, use of the wrench with corroded
steel structures or components should be avoided
whenever possible. Be especially careful to avoid
accidental impacts with the wrench and corroded
steel.
WARNING
To help prevent a mechanical spark hazard,
no components containing a magnesium content
greater than 7.5 percent have been used in the HMT-
Series torque wrench (in accordance with standard EN
13463-1).
• Take extreme care to prevent the HMT-Series
torque wrench from being dropped on the floor or
onto any other metallic surface that might cause
mechanical sparks at impact. Also, take every
precaution to prevent other tools (or other metallic
objects) from dropping onto the HMT-Series torque
wrench.
Electrostatic Discharge
• Electrostatic discharge is a potential source of
ignition and can result in electrostatic build-up
on isolated conductive parts. Isolated conductive
parts create capacitive poles which can become
charged. Electrostatic discharge risk is minimized
by the hydraulic hoses, which have multiple layers
of steel braiding, resulting in electrical continuity
between the torque wrench and the grounded
hydraulic pump.
• Non-conductive polyester labels could be a site
for electrostatic build-up. However, electrostatic
build-up is prevented by the close proximity of the
grounded torque wrench body.
NOTICE

6L4478_a
2. Compliance Statement(s)
2.2 ATEX Compliance Statement
In addition to the CE mark, the Enerpac HMT-Series
torque wrenches carry the ATEX mark and classification:
This classification indicates that the tool is appropriate
for use in a potentially explosive atmosphere.
The testing standards applicable to the HMT-Series
torque wrenches are the standard EN 13463-1:2009,
Non-electrical equipment for use in potentially explosive
atmospheres. Part 1: Basic method and requirements,
and also the draft standard of ISO/IEC 80079-36.
Contact Enerpac if there are any questions regarding the
ATEX classification or questions regarding application
of the HMT-Series torque wrenches in hazardous
environments.
●HMT1500 ●HMT3500 ●HMT7500
Ex II 2 G c T6
2.1 EU Declaration of Incorporation
Enerpac declares that this/ these product(s) has/ have
been tested and conforms to applicable standards and
is compatible to all CE Requirements.
A copy of an EU Declaration of Incorporation is enclosed
with each shipment of this product.
These tools conform with the
requirements for CE.
•HMT1500 •HMT3500 •HMT7500

L4478_a 7
3. Features & Components
3.1 Feature Diagram
Figure 1: Major features and components of HMT Drive Unit
Figure 2: Major features and components of HMT HLP Low Profile Cassette
1
2
3
4
5
6
7
8
1. Swivel Adaptor +
Hose Connections
2. Wrench Body
3. Fixed Pin
4. Rod End
5. Bottom Retaining Pin
6. Lanyard
7. Handle
8. Back Cap
1
6
2
4
5
7
3
8
1
3
4
5
6
2
1. Front Spacer
2. Ratchet Cassette Side Plate
3. Drive Plate
4. Hex Ratchet
5. Drive Pin
6. Bottom Retaining Pin
(part of the HMT Drive
Unit Assembly)
1
2
4
5
3
6

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Figure 3: Major features and components of HMT HSQ Square Drive Cassette
1. Square Drive Cassette Body
2. Drive Pin
3. Body Spacer
4. Drive Plate
5. Reaction Arm Spline
6. Reaction Arm Set Screw
7. Square Drive
8. Reaction Arm
9. Retaining Ring
10. Link Pin Assembly
11. Link Pin Assembly Lanyard
12. Square Drive Socket Attachment
12
8
11
1
2
3
4
5
6
7
9
10
11
6
2
4
5
8
7
3
9
10
12
1