Enerpac DSX1500 User manual

L4442
Rev. A
03/20
Dedicated Square Drive
Torque Wrench
DSX1500
DSX3000
DSX5000
DSX11000
DSX25000
ENGLISH [EN] Instruction Sheet

L4442
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CONTENTS
1.0 INTRODUCTION .........................................................................................................................................1
2.0 SAFETY .......................................................................................................................................................1
2.1 SAFETY PRECAUTIONS .....................................................................................................................2
3.0 FEATURES AND COMPONENTS...............................................................................................................5
4.0 CONNECTING THE TOOL.......................................................................................................................... 5
4.1 ATTACHING/ REMOVING SQUARE DRIVE.........................................................................................5
4.2 SELECTING DRIVE DIRECTION ..........................................................................................................5
4.3 ADJUSTING REACTION ARM.............................................................................................................. 6
4.4 ATTACHING HANDLE ...........................................................................................................................6
4.5 HOSE CONNECTION............................................................................................................................ 6
5.0 SETTING THE TORQUE .............................................................................................................................6
6.0 OPERATING THE WRENCH.......................................................................................................................7
6.1 BEFORE OPERATION........................................................................................................................... 7
6.2 TIGHTENING PROCESS.......................................................................................................................7
6.3 IN USE ...................................................................................................................................................7
6.4 NUT AND BOLT LOOSENING INFORMATION .................................................................................... 8
6.5 LOOSENING PROCEDURE.................................................................................................................. 8
7.0 MAINTENANCE...........................................................................................................................................8
7.1 PREVENTATIVE MAINTENANCE .........................................................................................................8
7.2 FULL MAINTENANCE.........................................................................................................................10
8.0 TROUBLESHOOTING ..............................................................................................................................15
9.0 TECHNICAL SPECIFICATIONS................................................................................................................16
9.1 CAPACITIES AND DIMENSIONS ....................................................................................................... 16

L4442 .1
1.0 INTRODUCTION
Overview
The DSX-Series hydraulic torque wrench is designed
for controlled tightening and loosening of fasteners in
industrial bolting applications. The DSX-Series includes
a Tether Ring that allows for safe installation and prevents
the torque wrench from dropping unexpectedly.
The DSX-Series can be used with a wide range of
Enerpac bolting pumps. Electric, air and hand style
pumps are available (sold separately).
Delivery Instructions
Upon delivery, all components must be inspected for
damage incurred during shipping. If damage is found,
the carrier should be notified at once. Shipping damage
is not covered by the Enerpac warranty.
Warranty
•Enerpac guarantees the product only for the
purpose for which is intended.
•Refer to the Enerpac Global Warranty document
for terms and conditions of the product warranty.
Any misuse or alteration invalidates the warranty.
•Observe all instructions as communicated in this
manual.
•Modification to any part of the equipment described
in this manual should not be attempted.
•When replacement parts are needed, use only
genuine Enerpac replacement parts.
Replacement Parts
Refer to the Repair Parts Sheet (RPS), available at
www.enerpac.com, to order replacement parts when
required.
EU Declaration of Conformity
DSX1500, DSX3000, DSX5000,
DSX11000, DSX25000
These tools conform with the
requirements for CE.
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 Conformity is enclosed
with each shipment of this product.
2.0 SAFETY
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

2L4442
2.1 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 o 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
DSX-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.
WARNING
•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.
•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 aect 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.

L4442 .3
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.
•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 coecient of friction. Be sure to know the
coecient of friction for the lubricant or anti-seize
compound that is being used. To ensure proper
tightening of nuts and bolts, always use this
coecient of friction when calculating required
torque values.
CAUTION
• 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

4L4442
Use of Torque Wrenches in Explosive Atmospheres
In addition to the CE mark, the Enerpac DSX-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 DSX-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 DSX-Series torque wrenches in hazardous
environments.
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 DSX-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 DSX-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 DSX-
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.
DSX1500, DSX3000, DSX5000,
DSX11000, DSX25000
CE Ex II 2 G c T6
WARNING
To help prevent a mechanical spark hazard,
no components containing a magnesium content
greater than 7.5 percent have been used in the DSX-
Series torque wrench (in accordance with standard EN
13463-1).
•Take extreme care to prevent the DSX-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 DSX-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

L4442 .5
3.0 FEATURES AND COMPONENTS
Figure 1: Major features and components of DSX Torque Wrench
To insert the drive in the tool, place the drive in the
desired direction and engage drive; then twist the drive
and bushing until ratchet spline can be engaged. Push
drive through ratchet. Depress drive retainer button,
engage retainer with drive and release button to lock.
Be sure that the square drive fits tightly into
the ratchet.
4.2 Selecting Drive Direction
The following diagram illustrates the direction the
square drive should face for loosening and tightening of
a standard right hand fastener:
Figure 3: Drive Directions for Loosening/ Tightening
•For tightening bolts, install the square drive in the
location shown in Figure 3.
•For loosening bolts, install the square drive on the
opposite side of the wrench.
WARNING
Right is tight.
Left is loose.
4.0 CONNECTING THE TOOL
4.1 Attaching/ Removing Square drive
Be sure that hydraulic pump is OFF and that
hydraulic system is depressurized (0 psi/bar) before
removing or attaching the square drive.
To remove the square drive, disengage the drive retainer
assembly by depressing the round center button and
gently pulling on the square end of the square drive. The
square drive will easily slide out.
Figure 2: Remove drive retainer
Note: The tether will keep the drive retainer attached
to the wrench body when removing and reposition the
square drive.
WARNING
1. Hose Connections
2. Swivel Adaptor
3. Wrench Body
4. Square Drive
5. Handle
6. Reaction Arm
7. Reaction Arm Reaction
Mechanism
8. Tether Ring
1
6
2
4
5
8
7
3

6L4442
4.3 Adjusting Reaction Arm
The reaction arms are employed to absorb and
counteract forces created as the unit operates, which
should extend in the same direction of the square drive;
however, slight adjustments may be made to suit your
particular application.
In operation, the reaction arm must be fully engaged
and secured. To engage the reaction arm, depress the
spring loaded button located on the rear of the end cap,
push to position and release to lock. Ensure the retainer
is locked in place prior to using the wrench.
To remove the reaction arm, depress the spring loaded
button located on the rear of the end cap and pull to
release.
Figure 4: Positioning Reaction Arm
4.4 Attaching Handle
Secure the positioning handle with thumb screw or
eyebolt. Handle can be installed on either side of wrench
(as needed).
Figure 5: Attaching Handle
4.5 Hose Connection
Be sure all hoses and fittings are rated for
at least 10,000 psi [690 bar] operation. Check that all
hydraulic couplings are securely connected before
operating the tool. Failure to observe these precautions
may result in the hoses bursting or disconnecting under
pressure. High pressure oil leakage may also occur.
Serious personal injury could result.
The torque wrench and hydraulic pump are connected
by a 10,000 PSI (700 Bar) twin-line hose assembly. On
each twin hydraulic hose, one line must be MALE-MALE
and the other line must be FEMALE-FEMALE in order to
ensure a correct interconnection between the pump and
wrench. Ensure the connectors are fully engaged and
screwed snugly together.
NEVER use two twin hydraulic hoses
between the pump and wrench. If so, you have the
high pressure on the retract side and your wrench is
not able to work properly. To avoid tool malfunction, do
not reverse connectors. Do not try to loosen the swivel
assembly at any moment.
Connect hoses to wrench as described in the following
steps:
•Be sure that all pressure in system is relieved and
that pressure gauge indicates zero psi/bar.
• Remove the hose dust caps.
•Connect the hose with the female coupling to the
wrench advance coupling.
•Connect the hose with the male coupling to the
wrench retract coupling.
•At each connection, pull the collar on the female
coupling over the male coupling. Engage threads
and hand tighten the collar.
•Connect the hoses to the pump.
Refer to the pump instruction manual:
Figure 6: Drive direction change
WARNING
CAUTION

L4442 .7
5.0 SETTING THE TORQUE
After determining the desired torque, use the calibration
certificate supplied with your wrench to determine the
pressure that is necessary to achieve that torque.
1. Connect the tool to the power supply and turn the
pump on.
2. Adjust the pressure on the pump as necessary
to set the torque. Refer to pump manufacturer's
instruction manual.
3. When the desired pressure is reached, cycle the
tool again to confirm that the desired pressure
setting has been obtained.
Figure 7: Using the Pump
6.0 OPERATING THE WRENCH
6.1 Before Operation
• Be sure the nut or bolt to be fastened is clean and
free of loose dust or dirt.
• Be sure the nut threads properly engage with the
threads of the bolt, and that cross-threading has
not occurred.
• Be sure that the threads and the bearing surface
are liberally coated with the correct bolt lubricant
or anti-seize compound.
• Make all torque calculations based on the bolt
lubricant's (or anti-seize compound's) stated
coecient of friction. Failure to do so may result in
the required bolt load not being achieved.
• Be sure that the backup wrench (used to keep the
nut or bolt on the opposite end in place) is correctly
positioned and secured.
Be certain that backup wrench is of the
correct size and that there is an adequate abutment
surface. Personal injury could occur if backup wrench
loosens or dislodges during bolting procedures.
WARNING
6.2 Tightening process
1. Having set your target pressure, cycle the wrench
three or four times to target pressure before putting
it on the application. Cycling the tool ensures the
system is operating properly and removes trapped
air, if any.
2. Place the correct size impact socket on the square
drive and secure properly with a ring and pin.
3. Place the tool and the socket on the nut, making
sure that the socket has fully engaged the nut.
Further ensure that the drive retainer is engaged.
4. Make sure the reaction arm is firmly abutted
against a stationary object (e.g. an adjacent nut,
flange, equipment housing etc.). When positioning
the wrench, make sure that the hose connections
are well clear of any obstructions, and that all body
parts are safely out of harms way.
Figure 8: Position tool with a suitable reaction point
5. Apply momentary pressure to the system to ensure
proper tool placement. If it doesn’t look or act right,
stop and readjust the reaction arm.
6.3 In use
1. Start the pump, the rear of the tool will be pushed
back until the reaction arm makes contact with its
reaction point.
2. Continue as the socket turns until the tool is fully
extended and will not turn the socket further; stop
the pump . Successive cycles are made until the
wrench stalls at the preset torque.
3. Operate the pump until the nut has been tightened.
4. While the pump is in operation there will be a rapid
build up of pressure to the point of where the
gauge reads what was preset prior to applying the
wrench.
The reading of full preset pressure after the
cylinder is extended does not indicate that this pressure
(torque) is applied to the bolt. It only indicates that the
cylinder is fully extended and cannot turn the socket
further until the wrench automatically resets itself.
5. Always attempt one final cycle to ensure the stall
point has been reached.
NOTICE

8L4442
6.4 Nut and Bolt Loosening Information
•Be aware that more torque is usually required to
loosen a fastener than to tighten it.
•Rusted fasteners (humidity corrosion) may require
up to twice the torque required for tightening.
•Fasteners that are corroded due to contact with
sea water or chemicals will require up to two and a
half times the torque required for tightening.
•Heat corrosion requires up to three times the
torque required for tightening.
Do not apply more than 75 percent of the
wrench’s maximum torque when loosening nuts or
bolts. Avoid making sudden start-stop movements
(“shock loading”). Failure to observe these precautions
may cause a catastrophic failure of the wrench to occur,
and wrench components under high tension could
become dangerous projectiles. Serious personal injury
could result.
6.5 Loosening Procedure
•Apply penetrating oil to the threads. Allow the oil
to soak.
•Set the pump to 10,000 psi (Loosening torque
equals about 100% of tightening torque).
•Change the drive and the reaction arm to the
loosening mode, ensuring the reaction arm abuts
squarely o a solid reaction point.
• Start the pump.
•Operate the pump until the nut has been loosened.
If the bolt / nut does not loosen with the
above procedure, it is an indication that you require the
next larger size DSX to loosen the bolt
7.0 MAINTENANCE
Lubrication frequency depends on factors known only
to the user. The amount of contaminants in the working
area is one factor. Wrenches used in a clean room
environment will obviously require less maintenance
than wrenches used outdoors and dropped in loose dirt
or sand.
1. When lubrication is required, lubricate all moving
parts.
2. Springs are used for the drive pawl assembly.
These springs can be replaced if necessary.
3. If the cylinder requires disassembly, it is
recommended that the cylinder seals be replaced
at the same time. Seal kits are readily available.
4. Hoses should be checked for cracks and leaks
before, and after each job. Hydraulic fittings can
become plugged with dirt and should be flushed
periodically.
5. Fittings should be kept clean and not allowed to
be dragged along the ground or floor as even small
particles of dirt can cause the internal valves to
malfunction.
WARNING
NOTICE
All structural parts on the tools should be inspected at
least once a year to determine if there are any cracks,
chips, or deformities.
Preventative maintenance can be performed by the
user.
Full maintenance must be performed only by an Enerpac
authorized service center or a qualified and experienced
technician.
7.1 Preventative Maintenance (Fig.9/ Fig.10)
1. Check tightness of swivel assembly retaining
screws (40) and piston sleeve (7) (see Section 7.2).
2. Pressurize the wrench to 10,000 psi [690 bar]
pressure (in both advance and retract), and check
for any signs of leakage.
3. Relieve pressure and disconnect hydraulic hoses.
4. Clean all exposed components with a mild solvent.
5. Remove the shroud screws (11) and remove the
shroud (27). The tether (37) will continue to link the
shroud to the drive release assembly. To remove
the tether unscrew the round screw, slide o the
washer, and remove the tether line.
6. Remove the square drive (8) and drive retaining
release assembly (12, 13, 14) along with the two
bushes and drive retainer (9, 26)
7. Disengage the two access plugs (21), and slide out
the rod end pin (18). The drive plate (3) can now
separated from the wrench body (1).
8. Remove the ratchet (4), pawl (5) and pawl wave
springs (6).
9. Clean all components with a mild solvent.
10. Inspect all parts for damage. Any damaged
components must be replaced.
11. Dry all components. Apply a thin coat of
molybdenum disulphide grease in the areas shown
in Figure 10.
Be sure that the ratchet, drive plate, pawl,
pawl wave spring, square drive, and access plugs are
correctly installed in the following step. Ensure that the
square drive is inserted through the drive plate and rod
end of the piston assembly before installing the access
plugs. Failure to install these parts correctly will result in
component damage. Refer to figures 9 and 10.
12. Connect the wrench to the pump.
13. With wrench not on nut or bolt, check operation
at a nominal pressure to make sure the piston
advances and retracts freely.
14. Release the pressure and make sure that the piston
fully retracts.
NOTICE

L4442 .9
21
18
11�
6
5
27
8
26
9
13
9
3
4
21 1
14
12
37
LP1
�
LP2
�
�
LP4
�
LP5
�
LP6
LP7
�
�LP13
�
LP8 �
LP9 �
LP10 �
LP11 �
LP12
�LP14
�LP15
LP16
�
LP3 �
LP17
�
Figure 9: Exploded Torque Wrench Head
Figure 10: Torque Wrench Head Lubrication Points
Lubrication Points - Molybdenum Disulphide Grease:
LP1 Pawl (All Surfaces) LP7 Inner Surface LP13 All Surfaces
LP2 Bearing Surface LP8 Bearing Surface LP14 Bearing Surface
LP3 Wrench Body Inner Surfaces LP9 Bearing Surface LP15 Bearing Surface
LP4 Square Drive Bearing LP10 Bearing Surface LP16 Front Faces
LP5 Square Drive Bearing LP11 Bearing Surface LP17 Teeth and Outer Surfaces
LP6 Bearing Surface LP12 Bearing and Inner Surface
✜ molybdenum disulphide grease
❇ Apply Loctite 222 Thread Sealant
✲ Tighten to Torque Value of 1.2 Ft.lbs [1.6 Nm]

10 L4442
7.2 Full Maintenance
7.2.1 Hydraulic Swivel Assembly (Fig.11)
Disassembly of Swivel Post and Swivel Assembly
Attachment
1. Remove the circlip (A) from the top of the swivel
post (F).
2. Using a pair of flat blade screwdrivers, gently pry
the swivel assembly (B) from the swivel post (F).
3. Remove the socket head capscrews (C) and the
swivel post (E).
4. Remove O-rings (F) from the swivel post hydraulic
ports.
5. Remove O-ring (D) from the swivel post (F).
Replacing Hydraulic Couplings (Fig. 10)
Use a vise with soft jaws to hold the swivel
when removing and installing hydraulic fittings in the
following steps. To prevent possible damage to wrench,
never attempt to tighten the hydraulic fittings while the
swivel is installed on the wrench.
1. Place the swivel assembly in a vise with soft jaws,
and remove the old male coupling (B1), and female
coupling (B2).
2. In preparation for reinstallation, remove any
deposits of dried thread sealant remaining on the
threads of the swivel assembly (B).
Inspect all components before reassembly.
Always replace any worn or damaged parts with new
ones.
3. Install new hydraulic fittings by hand. Then, use a
wrench to tighten them. Follow steps 6 through 9.
4. Coat the threads on the swivel end of the male
coupling (B1) with Loctite 577 thread sealant.
Thread the coupling into the advance port (marked
“A”) of the swivel (B).
5. Tighten the coupling (B1) by hand, until it is installed
finger-tight. Then, wrench tighten the coupling an
additional 2 to 3 turns beyond finger tight.
6. Coat the threads on the swivel end of the female
coupling (B2) with Loctite 577 thread sealant.
Thread the coupling into the retract port (marked
“B”) of the swivel (B).
7. Tighten the coupling (B2) by hand, until it is installed
finger-tight. Then, wrench tighten the coupling an
additional 2 to 3 turns beyond finger tight.
8. Allow sealant sucient time to cure (refer to
NOTICE statement after this step).
To allow the sealant sucient time to cure,
wait a minimum period of 3 hours at 68 to 104°F [20
to 40°C], or 6 hours at 40 to 68°F [5 to 20°C] before
pressurizing the wrench.
NOTICE
NOTICE
NOTICE
Figure 11: Removing Swivel Post and Swivel Assembly
Rebuilding the Swivel Assembly (Fig.12)
• Disassembly
Following removing the swivel assembly from the swivel
post and removing the hydraulic fittings from the swivel.
1. Loosen and remove socket head capscrew (B8).
2. Firmly rotate swivel arm “A” (B3) and swivel arm
“B” (B4) in opposite directions until they become
disengaged from the swivel manifold block. (B5).
3. Firmly pull swivel arm “A” (B3) and swivel arm “B”
(B4) o of the posts of the swivel manifold block
(B5).
4. Removing blanking screws (B7)
5. Remove and discard O-rings (B6).
Inspect all components before reassembly.
Always replace any worn or damaged parts with new
parts. Remove any dirt, old grease or old sealant from
reusable parts and make sure that they are clean.
NOTICE
A
E
B
D✤
✤D
✤F
�C
C�
✽
G
✽
✽
✽
✤Apply silicone grease
to O-rings.
✽Apply Loctite 243
Thread Sealant
(inside bolt holes)
󳮢
Tighten to Torque Value
of 5.9 Ft.lbs [8 Nm]

L4442 .11
• Reassembly
1. Install new O-rings (B6) into the grooves on the
posts of the swivel manifold block (B5). Apply
silicone grease to O-rings as installed.
2. Reinstall blanking screws (B7)
3. Reinstall swivel arm “A” (B3) and swivel arm “B”
(B4) on the posts of the swivel manifold block (B5).
4. Rotate the swivel arms (B3 and B4) toward each
other until the tabs are fully engaged in the notches.
5. Coat the threads of the socket head capscrew
(B8) with Loctite 243 thread sealant. Tighten the
capscrew securely. To allow the sealant sucient
time to cure, wait a minimum period of 3 hours at
68 to 104°F [20 to 40°C], or 6 hours at 40 to 68°F [5
to 20°C] before pressurizing the wrench.
Capscrew (B8) must remain tightly installed.
Never operate wrench with capscrew (B8) loosened
or missing. Serious personal injury and/or damage to
wrench components may result if swivel arms become
loose and/or separated while the wrench is under
pressure.
WARNING
Installation of the Swivel Post and Swivel Assembly
(Fig.11)
•Attaching the Swivel Post
1. Apply a small amount of Loctite 243 thread sealant
to the threaded mounting holes in the wrench
housing. See Fig. 11 for locations.
2. Install two new O-rings (F) into the ports on the
base of the swivel post (E).
3. Place the swivel post (E) onto the wrench (G),
making sure that hydraulic ports are aligned. Be
careful that the O-rings (F) do not drop out or
become pinched or cut.
4. Install the degreased socket head capscrews (C)
and tighten to 5.9 Ft.lbs [8 Nm]
•Attaching Swivel Assembly to Swivel Post
1. Install a new O-rings (D) into the grooves on the
swivel post (E).
2. Coat O-rings (D) with a small amount of silicone
grease. Then, carefully slide the swivel assembly
(B) onto the swivel post (E).
3. Reinstall the circlip retainer ring (A).
4. Perform hydraulic pressure testing before placing
the wrench into service. Refer to the procedure in
Section 7.2.3
B3
B6
✤B5
B7
✤B4
B8✽
�B1
�B2
A
B6
✤
B7
✤


 Tighten to Torque Value of 1.2 Ft.lbs
[1.6Nm]
Figure 12: Exploded Swivel Assembly
✤Apply silicone grease to O-rings.
✽Apply Loctite 243 Thread Sealant
(item B8)
󳗠
Apply Loctite 577 Thread Sealant
(thread of B1 and B2)

12 L4442
7.2.2 Piston Assembly (Fig. 13/ Fig.14)
• Disassembly
1. To separate the reaction arm from the wrench body
(1) unscrew and remove the wire assembly first
by unscrewing the nut followed by the rest of the
assembly (36).
2. Remove drive plate, pawl, ratchet, rod end pin,
access plugs and other related parts as described
in sections 7.1.
3. Firmly hold the wrench body (1). Using an
appropriate pin spanner, unscrew and remove
the piston sleeve (7), followed by the freed piston
assembly. Remove the O-ring (32) from the piston
sleeve.
4. DSX11000/ DSX25000 only - remove the grub
screw (39) and ball bearing (38) from the wrench
body for inspection and cleaning. Reassembly
after Loctite 577 has been applied. Loctite must be
fully cured before testing.
5. Remove seal from piston head (22) separate rod
end (17) from piston rod (20) separate piston head
(22) from piston (19) remove internal O-Ring from
piston head.
6. Remove the rod seal (28) and piston bush (23) if
they are still present in the wrench body.
7. Clean all exposed components with a mild solvent.
8. Inspect all parts for damage.
•Reassembly and Installation (Fig. 13/ Fig.14)
Do not use excessive force when installing
the piston rod (20) or piston (19) in the following
steps. Excessive force may cause damage to these
components and also may damage the sealing faces
within the wrench.
NOTICE
In the following steps, lubricate all O-rings
with ISO 10 grade oil:
1. Fit piston head o-ring (31) into the piston head (22)
2. Slide Piston Rod (20) into the piston (19). Apply
Threadlock to the external threads of the piston (19)
and screw onto piston head (22), encapsulating
the piston rod (20) within and tighten.
3. Apply threadlock to the Rod End (17) threads and
install into the Piston Rod (20), holding the Piston
Rod with a spanner to prevent rotation.
4. Install Piston O-ring (30) into the external groove of
the piston head (22).
•Reassembly (DSX1500/ DSX3000/ DSX5000)
5. Insert Piston Bush (23) into the body, followed by
the Rod Seal (28) and Piston O-ring (29).
6. Install Piston Sleeve O-ring (32) into the external
groove of the Piston Sleeve (7).
•Reassembly (DSX11000/ DSX25000)
5. Insert Piston Bush (23) into the body(1), followed
by the Rod Seal (28)
6. Install Back Cap O-ring (32) into the groove on the
Back Cap (7).
7. Install the Back Cap Thread O-Ring (29) into the
groove in the body (1)
NOTE: Ensure the grub screw (39) and ball bearing
(38) have been installed after Loctite 577 has been
applied. Loctite must be fully cured before testing.
NOTICE
31
󳾭
20
19

28
󳾭
23
󳾭
17

1
22
󳾭
30

7
󳾿
36
󳾭
32
󳾭
29
✫Apply ISO 10 grade oil to O-rings.
✽Apply Loctite 243 Thread Sealant
󳾼Apply Threadlock
Figure 13: Exploded DSX1500, DSX3000, DSX5000 Pistons
⁂ See 7.2.2, step 9, Installation for
Torque Values

L4442 .13
• Installing
8. To Insert the completed piston assembly, first
ensure that the ratchet system is in place. The
assembly can be secured by inserting the rod end
plug (18) and access plugs (21).
9. Tighten Piston Sleeve / Back Cap to the following
Torque values:
• DSX1500 : 60Nm
• DSX3000 : 60Nm
• DSX5000 : 150Nm
• DSX11000 : 160Nm
• DSX25000 : 200Nm
10. Reassemble drive plate (3), pawl (5), ratchet (4), rod
end pin (18), access plugs (21) and other related
components in the reverse order of disassembly.
Refer to Section 7.1.
11. If removed, reinstall the hydraulic swivel and swivel
post. Refer to Section 7.2.1.
12. Reinstall the reaction arm assembly.
13. Perform hydraulic pressure testing before placing
the wrench into service. Refer to the procedure in
Section 7.2.4.
7.2.3 Hydraulic Pressure Testing
•Connect hydraulic hoses and cycle the wrench at
1,000 psi [69 bar] to check for oil leaks.
•If there are no leaks, cycle the wrench at 10,000 psi
[690 bar] and check again for leaks.
•If leaks are present, determine the cause and make
repairs as required before placing the wrench into
service.
Pressurized hydraulic oil can penetrate the
skin and could cause serious personal injury. Always
repair any oil leaks before using the wrench.
WARNING
30
󳾭
2019

28
󳾭
23
󳾭
1
22
󳾭
29

7
󳾿
36
󳾭
29
󳾭
31

17
38
󳾶
39
󳾶
★Apply ISO 10 grade oil to O-rings.
✽Apply Loctite 243 Thread Sealant
󳗠
Apply Loctite 577 Thread Sealant
Figure 14: Exploded DSX11000, DSX25000 Pistons
Figure 15: Sectional View Positioning Piston and Drive
Plate
󳾼Apply Threadlock
⁂ See 7.2.2, step 9, Installation for
Torque Values

14 L4442
7.2.4 Reaction Arm - Disassembly and Reassembly
(Fig. 16)
• Disassembly
1. To remove the wire assembly (36) that is securing
the reaction arm to the wrench body, first unscrew
the wire assembly nut followed by the rest of the
assembly (36).
2. Remove the reaction arm assembly, including the
retaining plate (4), and shackle ring (38).
3. Unscrew the two plate screws (35) and remove
retainer (24).
4. Remove the grub screw (10), followed by the
retainer tab (15) and spring (16).
5. If required, the shackle ring can be removed from
the reaction arm body by removing the eyebolt
assembly and separating the shackle ring arms.
6. Clean all exposed components with a mild solvent.
7. Inspect all parts for damage. Replace any worn or
damaged parts.
•Reassembly and Installation
1. Apply silicon lubricate to all components, except
the two plate screws (35).
2. Re-assemble the spring (16), retainer tab (15), and
grub screw (10), applying a small amount of Loctite
222 thread sealant on to the grub screw before
installing the assembly into the retainer plate (24).
3. Fit the retainer plate (24) into the reaction arm body
(2), apply a small amount of Loctite 243 thread
sealant to the threaded mounting holes before
inserting plate screws (35).
4. If removed, reattach the shackle ring (38), secured
into place with the eyebolt. Loctite 222 should be
applied to the thread of the eyebolt during assembly.
5. Install the wire assembly (36) into the rear of the
piston sleeve. Slide the reaction arm (2) onto the
wrench body (1), threading the end of the wire
assembly (36) through the retainer plate (24) and
secure by screwing the hex nut onto the end of the
wire assembly (36).
7.2.5 Square drive Release Button Disassembly
and Reassembly (Fig. 17)
Disassemble the square drive release button
only if it is not operating properly or if it is worn or
damaged.
1. Remove circlip (13).
2. Separate the button mechanism (12) from the
retaining block (14).
3. Clean all parts with a mild solvent. Dry all parts
after cleaning.
4. Inspect all parts for damage.
5. Reassemble retaining button assembly (12) and
bushing (14) and secure with circlip (13).
6. Apply a thin coat of molybdenum disulphide grease
in the areas shown in Figure 10.
NOTICE
13
14 12
37
Figure 17: Exploded Square drive
38
✽35
33
25
24
16
15
10
❇
2
❇
(eyebolt thread
only)
Figure 16: Exploded Reaction Arm
❇ Apply Loctite 222 Thread Sealant
✽Apply Loctite 243 Thread Sealant
If a fault develops with the retaining button
assembly (12), the whole assembly will need to be
replaced. It is not recommended that this item be
disassembled.
NOTICE

L4442 .15
8.0 TROUBLESHOOTING
Fault Possible Cause Corrective Action
Wrench pressure will not build Piston seal and/or end plug seal
leaking
Replace any defective o-rings.
Coupler is defective Replace any defective couplers.
Cylinder / Tool Leaks Blown o-ring in cylinder Replace seal kit.
Defective piston rod seal Return to Enerpac for repair.
Tool operates backwards Couplings/ hose connections
reversed
Check couplings and correct.
Ratchet returns with retract stroke Broken or otherwise inoperable
drive segment
Replace drive segment and/or
spring. Return to Enerpac.
Ratchet will not take successive
strokes
Broken or otherwise inoperative
drive segment or spring
Replace drive segment and/or
spring. Return to Enerpac.
Cylinder not retracting completely Remove tool from nut and cycle
freely for several strokes.
Allow adequate time for cylinder to
retract fully.
If problem persists, check pawls.
Linkage between piston rod and
drive plate is broken
Replace parts as necessary - return
to Enerpac.
Cylinder will not retract Voltage to electric pump is too low
to line drop or inadequate amperage
is available
Get shorter extension cord. If shop
power is adequate, draw power
from welding machine or cal. rod
transformer.
Linkage between piston rod and
drive arms are broken
Replace part as necessary
Tool locks on to nut Drive segment is loaded when the
tool is maxed out in torque
Pressure advance on remote and
build pressure - continue to press
down on remote while pulling back
on one of the accuracy assurance
levers - release remote while
continuing to hold back on levers.
Tool is operating backwards Push advance button down - tool
should immediately fall free.
Tool is wedged under a fixed object Remove shroud from around
ratchet. Pry the drive segment out
of the ratchet and at the same time
pull back on the accuracy assurance
levers. Tool should swing free or
burn away the socket or obstruction.
Tool operates backwards Multiple hoses in even numbers Configure hoses in odd multiples
only.
Refer to the Pump Instruction Sheet for troubleshooting required for the pump unit.

16 L4442
9.0 TECHNICAL SPECIFICATIONS
9.1 Capacities and Dimensions
Figure 6
Model Number
DSX1500 DSX3000 DSX5000 DSX11000 DSX25000
Square drive inch
3⁄4
1 1
1⁄2
1
1⁄2
2
1⁄2
Maximum Operating
Pressure
psi 10,000 10,000 10,000 10,000 10,000
bar 690 690 690 690 690
Nominal
Torque
at 10,000 psi Ft.lbs 1411 3233 5635 11,524 24,057
at 690 bar Nm 1913 4383 7640 15,624 32,617
Minimum
Torque
Ft.lbs 141 323 563 1152 2406
Nm 191 438 764 1562 3262
Weight lbs 4.85 10.58 17.86 31.75 71.65
kg 2.2 4.8 8.1 14.4 32.5
Dimensions A inch [mm]
1.73 [44] 2.28 [58] 2.72 [69] 3.43 [87] 4.61 [117]
B
inch [mm]
2.64 [67] 3.39 [86] 4.41 [112] 5.08 [129] 6.93 [176]
C
inch [mm]
4.21 [107] 5.67 [144] 6.81 [173] 8.46 [215] 11.34 [288]
D
inch [mm]
3.78 [96] 5.08 [129] 5.83 [148] 7.13 [181] 9.61 [244]
E
inch [mm]
5.71 [145] 6.73 [171] 7.56 [192] 8.74 [222] 10.47 [266]
F
inch [mm]
0.94 [24] 1.26 [32] 1.5 [38] 1.89 [48] 2.25 [64]
G
inch [mm]
4.49 [114] 5.83 [148] 7.09 [180] 8.94 [227] 11.06 [281]
H inch [mm]
6.42 [163] 8.46 [215] 10.24 [260] 12.8 [325] 16.77 [426]
A
B
C
F
G
H
D
E

NOTES
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L4442 .17

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