Enerpac W Series User manual

Instruction Sheet
W-Series Hydraulic Torque Wrench
W2000SL and W4000SL UltraSlim
L4116
English (EN) Rev. D 11/2015

2
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ENGLISH

Instruction Sheet W-series
Torque Wrenches
3
Index
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Assembly and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7 Replacement Parts and Recommended Tools . . . . . . . . . . . . . . . . . . . . . 32
W2000SL and W4000SL
UltraSlim
ENGLISHENGLISH

4
1 Introduction
Overview
The Enerpac W-Series hydraulic torque
wrench is designed for controlled
tightening and loosening of fasteners
in industrial bolting applications. The
W-Series features a low profile cassette,
compact drive unit and integrated reaction
foot, making it ideal for use in locations
where workspace is limited.
Interchangeable W-Series UltraSlim
cassettes are available in an assortment
of popular sizes to suit specific customer
requirements.
An optional TSP Pro Series Swivel
provides 360 degree X-axis and 160
degree Y-axis rotation, allowing easier
positioning of the wrench and hoses in
confined areas.
The W-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.
• All Enerpac products are guaranteed
against defects in workmanship and
materials for as long as you own them.
Any misuse or alteration invalidates the
warranty.
• Observe all instructions as
communicated in this manual.
• When replacement parts are needed, use
only genuine Enerpac replacement parts.
EU Declaration of Incorporation
• W2000SL • W4000SL
These tools conform with the
requirements for CE Marking.
Enerpac declares that the W-Series
models listed above meet the applicable
standards and directives issued by the
European Union.
For additional details, refer to the separate
EU Declaration of Incorporation.
2 Safety
Read all instructions carefully. Follow all
recommended safety precautions to avoid
personal injury as well as damage to the
wrench 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 any questions or concerns
arise, contact Enerpac or a local Enerpac
distributor for clarification.
If you have never been trained on high-
pressure hydraulic safety, consult your
distributor or service center for a free
Enerpac Hydraulic Safety Course.
This manual follows a system of safety
alert symbols, signal 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 personal
injury.
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5
• 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.
• Stop operation immediately if a gap
appears between the drive unit locating
plate (on the cassette) and the drive unit
housing. Have the tool inspected and
repaired before it is operated again.
• Maximum allowable pressure for the
W-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
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.
DANGER Indicates a hazardous
situation that, if not avoided, will result in
death or serious personal injury.
WARNING Indicates a hazardous
situation that, if not avoided, could result in
death or serious personal injury.
CAUTION Indicates a hazardous
situation that, if not avoided, could result in
minor or moderate personal injury.
NOTICE Indicates information considered
important, but not hazard related (e.g.
messages relating to property damage).
Please note that the Safety Alert Symbol
will not be used with this signal word.
2.1 Safety Precautions - W-Series
Hydraulic Torque Wrenches
WARNING
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 headwear, 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 coworkers.
• 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.
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6
hydraulic pressure. If the couplings
are not fully connected, oil flow will
be blocked, and the drive unit could
be subjected to excessive hydraulic
pressures. Catastrophic failure of wrench
could result.
• Never operate the wrench if it is known
or suspected that the drive unit retaining
pin is worn, bent, missing or damaged.
Drive unit could disengage from the
cassette and become a dangerous
projectile.
• Never operate the wrench if the drive
unit release handle cannot be fully
closed when the drive unit is installed on
the cassette. Drive unit could disengage
from the cassette and become a
dangerous projectile.
• Never attempt to force the drive unit
onto the cassette if it becomes difficult
to install. Have the drive unit and
cassette inspected and repaired before
placing the wrench back into service.
• 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 nonflammable
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 worksite.
Be certain there is adequate ventilation
when using solvent.
CAUTION
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.
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7
• 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 ratchet 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 ratchet 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
ratchet 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.
NOTICE
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 (see Section 5).
• Check that the swivel post capscrews
and drive unit cylinder gland are tight
prior to use. (see Section 5)
• If oil leakage is present from drive unit,
replace seals as required (see Section
5) before placing the drive unit 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.
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8
Use of Torque Wrenches in Explosive
Atmospheres
In addition to the CE mark, the Enerpac
W-Series UltraSlim torque wrenches carry
the ATEX mark and classification:
• W2000SL • W4000SL
CE Ex II 2 GD cT4
This classification indicates that the tool is
appropriate for use in a potentially
explosive atmosphere.
The testing standards applicable to
the W-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
W-Series torque wrenches in hazardous
environments.
Reducing the Risk of Explosion
WARNING
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 W-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 W-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 W-Series torque wrench to minimize
the possibility of an incendive spark
that may be caused by the impact of
aluminum components with corroded
steel. However, to reduce the chance
of an incendive 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.
NOTICE To help prevent a mechanical
spark hazard, no components containing a
magnesium content greater than 7.5
percent have been used in the W-Series
torque wrench (in accordance with
standard EN 13463-1).
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9
• Take extreme care to prevent the
W-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 precation to prevent other tools
(or other metallic objects) from dropping
onto the W-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.
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10
3 Assembly and Adjustments
3.1 Overview and features (Fig. 1 or 2)
1 Ratchet (12-Point, Bi-Hex)
2 Cassette
3A Hydraulic Swivel (standard)
3B TSP Pro Series Swivel (optional)
4 Advance hose connection
5 Return hose connection
6 Hydraulic drive unit
7 Cassette release lever
8 Reaction foot
3.2 To install the positioning handle (Fig. 3)
• Install the positioning handle (9) by fully
screwing the threaded end into the
tapped hole (10) on top of wrench.
3.3 Changing the Cassette
WARNING Be sure that hydraulic
pump is OFF and that hydraulic system is
depressurized (0 psi/bar) before removing
or attaching the cassette. Drive unit
could eject under force if this precaution
is not followed, resulting in possible
personal injury.
3.3.1 To Remove the Cassette
(Fig. 4 and 5)
• Be sure the drive unit piston is fully
retracted.
• Firmly grasp the cassette housing
with your hand or place the tool on a
workbench.
NOTICE Cass
ette will disengage from drive
unit in the following steps. Be sure to support
the cassette so that it does not drop.
• Pull the cassette release lever (7)
outwards.
• Remove the hydraulic drive unit (6) from
the cassette (2).
Fig. 1
Fig. 3
Fig. 2
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11
3.3.2 To Attach the Cassette
(Fig. 4 and 5)
• Pull the release lever (7) outwards.
• Be sure the retract link (11) aligns with
the slot (13) in the ratchet lever. Rotate
the piston rod if necessary.
• Slide the drive unit onto the cassette and
push the spigot (12) through the opening
in the drive unit locating plate (14).
• Push the release lever (7) back into the
cassette (2). Be sure the ball detent
clicks into place. Check that cassette
release lever is fully closed.
CAUTION Do not operate the tool if
the cassette release lever is not fully
closed. Drive unit could be ejected with
great force if lever is not fully closed,
Personal injury and/or damage to tool
could result.
3.4 To Connect the Hoses (Fig. 6)
WARNING 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 tool is fitted with male and female 1/4
inch NPTF spin-on hydraulic couplings.
Use Enerpac twin safety hoses only. Refer
to the table below.
Enerpac hose
model number Description
THQ-706T Two hoses, 19.5 feet
[6 m] long
THQ-712T Two hoses, 39 feet
[12 m] long
Fig. 4
Fig. 6
Fig. 5
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12
• Contact Enerpac for additional guidance
if a suitable reaction point is not
available.
4.2 Setting the Torque
Adjust the pressure on the pump as
necessary to set the torque. Refer to pump
manufacturer's instruction manual.
4.3 Wrench Operation
WARNING
Failure to observe the following
precautions could result in serious
personal injury:
• Stop operation immediately if a gap
appears between the drive unit locating
plate and the drive unit. A gap in this
location indicates that the drive unit
retaining pin is worn or damaged, and
must be repaired. Use of wrench with
worn or damaged retaining pin may
result in the drive unit forcefully ejecting
from the cassette.
• Never strike the tool with a hammer
or other object while it is under load.
Catastrophic failure of the wrench
could occur, and dislodged parts
could become dangerous projectiles.
Uncontrolled release of hydraulic oil
could also occur. Refer to Section 2 of
this manual for additional information.
4.3.1 Tightening a Nut or Bolt
(Fig. 7 and 8)
• Position the tool on the nut or bolt with
the clockwise (+) side facing upwards.
• Position the reaction foot (17) against a
suitable reaction point (18). The reaction
point will counteract the force caused by
operating the tool.
• Start the pump.
• Operate the pump until the nut or bolt
has been tightened to the required
torque.
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 (0) psi/bar.
• Remove the hose dust caps.
• Connect the hose with the female
coupling (15) to the wrench advance
coupling (4).
• Connect the hose with the male coupling
(16) to the wrench return coupling (5).
•
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.
4 Operation
4.1 Prior to 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 coefficient 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.
WARNING 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.
ENGLISH

13
Fig. 8
Fig. 7
Fig. 9
• Stop the pump immediately after work
has finished.
4.3.2 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.
WARNING 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.
4.3.3 Loosening a Nut or Bolt
(Fig. 9 and 10)
• Apply penetrating oil to the threads.
Allow the oil to soak.
• Position the tool on the nut or bolt
with the anti-clockwise (-) side facing
upwards.
• Position the reaction foot (17) against a
suitable reaction point (18). The reaction
point will counteract the force caused by
operating the tool.
• Start the pump.
• Operate pump until nut or bolt is loose.
If the nut or bolt will be re-used, avoid
excess load when loosening.
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14
WARNING During loosening, a nut or
bolt may be subjected to stresses
beyond its material limits, which could
result in a permanent reduction of its
strength. This reduction could lead to
catastrophic failure of the nut, bolt or
joint if the fastener is reinstalled. If there
is any doubt as to whether the force used
during loosening has caused excessive
stress, the removed fastener(s) should be
discarded and replaced with new
fasteners of the proper specifications.
4.3.4 Using an Extended Reaction Arm
(Fig. 11)
• Position the WTE Series extended
reaction arm (19) against a suitable
reaction point. The reaction point will
counteract the force caused by operating
the tool.
• Follow instructions in sections 4.3.1
through 4.3.3.
4.3.5 Using a Reaction Paddle (Fig. 12)
• Position the WRP Series reaction paddle
(20) against a suitable reaction point. The
reaction point will counteract the force
caused by operating the tool.
• Follow instructions in sections 4.3.1
through 4.3.3.
5 Maintenance and Troubleshooting
5.1 Introduction
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.
Fig. 10
Fig. 12
Fig. 11
ENGLISH

15
Recommended service intervals are:
a) 3 months – Heavy Duty use
b) 6 months – Normal use
c) 12 months – Infrequent use
Non destructive testing must be carried
out if the tool has been used under severe
conditions.
5.2 Preventative Maintenance -
Hydraulic Swivel and Drive Unit
(Fig. 13 and 14)
• Check tightness of swivel post
capscrews and gland (see Section 5.3).
• Pressurize the drive unit to maximum
pressure (advance and retract), and
check for any signs of leakage.
• Any damaged components or seals must
be replaced.
• Dry all components and apply a thin
coat of molybdenum disulphide grease
as indicated (✜).
5.3 Full Maintenance - Hydraulic Swivel
and Drive Unit (Fig. 14, 15 and 17)
Disassembly:
• Remove the circlip (A).
• Using a pair of flat blade screwdrivers,
gently pry the swivel assembly (B) from
the swivel post (F).
Fig. 14
✜✜
Fig. 13
E
F
G
B
C
B
A
H
✽
✽
◆
◆
◆
◆
✤
✤
✤
D
D
Standard
Swivel
TSP Pro
Series Swivel
✜ molybdenum disulphide grease ✽ Loctite 243
◆ Loctite 577
Thread Sealant:
✤ Silicone Grease
ENGLISH

16
• Remove O-rings (C) from the grooves inside
the swivel assembly (B).
• Place the swivel assembly in a vise
with soft jaws. Remove the hydraulic
couplings (B1, B2 and B3) from the
swivel assembly (B).
NOTICE For drive units equipped with the
optional TSP Pro Series swivel, refer to Enerpac
instruction sheet L2905 for additional
disassembly instructions.
• Remove the socket head capscrews (D)
and the swivel post (F) from the drive
unit (H). Remove O-rings (G) from the
swivel post hydraulic ports.
•
Remove O-ring (E) from the swivel post (F).
• Firmly hold the drive unit housing (H2).
Using an appropriate pin spanner,
unscrew and remove the cylinder gland
(H9). Remove O-ring (H8) from the gland.
• At the Spigot End of the drive unit, hold
the two flat sides of the piston rod (H1)
with a spanner wrench.
• Remove the piston retaining screw (H7)
from the piston (H6).
• Remove the piston rod (H1) from the
Spigot End of the drive unit housing (H2).
• Using a suitable drift, remove the piston
(H6) from the Gland End of the drive unit
housing (H2).
• Remove O-ring (H4) from the groove on
inside of piston (H6).
• Remove seal (H5) from the groove on
outside of piston (H6).
• Remove seal (H3) from groove inside
drive unit housing (H2).
• Clean all exposed components with a
mild solvent.
• Inspect all parts for damage.
• Perform magnetic particle inspection on
the following components:
- Drive unit housing (H2)
- Piston rod (H1)
Reassembly:
NOTICE In the following steps, coat all
O-rings and seals with silicone grease
before installation.
• Install seal (H5) in groove on outside of
piston (H6).
• Install seal (H3) in groove inside drive
unit housing (H2). Be sure that “V” side
of seal is facing toward the Gland End of
housing (H2).
NOTICE During reassembly in the
following steps, be sure that the piston rod
(H1) is inserted through the Spigot End of
the housing (H2).
NOTICE
Do not use excessive force when
installing the piston. This may damage the
piston and sealing faces within the drive unit.
• Coat the piston rod (H1) with silicone
grease and carefully slide it through the
Spigot End opening of the housing (H2).
• Assemble the piston (H6) on the end of
the piston rod (H1). Gently tap the piston
(H6) into place against the piston rod (H1).
WARNING
Be certain that piston
retaining screw (H7) is securely tightened in
the following step. If screw is not tight, piston
rod (H1) could be ejected from drive unit
when hydraulic power is applied. Serious
personal injury could result.
• Apply Loctite 243 thread sealant to the
threads of the piston retaining screw
(H7) before installation. Tighten piston
retaining screw securely.
• Install O-ring (H8) in groove on gland
(H9).
• Screw the gland (H9) into the drive unit
housing (H2) by hand, making sure that
the O-ring (H8) is not pinched or cut.
• Using an appropriate pin spanner,
fully tighten the gland (H9). Tap the pin
spanner with a suitable mallet to ensure
that gland (H9) is tightly installed.
ENGLISH

Fig. 15
✽
✤
✤
✤
✤
✤
H1
H2
H3
H4 H5
H6
H7
H8
H9
17
Fig. 16
✜
K1
K2
K3
K4
K5
K6
K7
K8 ✪
K12
K3
✲
❉
✲
✜ molybdenum disulphide grease
✲ See Fig. 18 for lubrication details
✪ See Fig. 19 for lubrication details
❉ See Fig. 20 for lubrication details
✽ Loctite 243 Thread Sealant
(Spigot End)
(Gland End)
✤ Silicone Grease
Item H3: “V” side of seal
must face toward Gland End.
K11
K10
K9
Refer to Figs. 14 and 17 for swivel components.
ENGLISHENGLISH

18
• Tighten the couplings (B1 and B3) and
adapter (B2) by hand, until they are each
finger tight. Then, wrench tighten these
parts an additional 2 to 3 turns beyond
finger tight.
NOTICE To allow the sealant sufficient
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 drive unit.
•
Install a O-ring (E) into the groove on the
swivel post (F).
• Install O-rings (C) into the grooves inside
the swivel assembly (B).
• Coat O-rings (E and C) with a small
amount of silicone grease. Then,
carefully slide the swivel assembly (B)
onto the swivel post (F).
• Reinstall the circlip retainer ring (A).
• Connect hydraulic hoses and cycle the
drive unit at 1,000 psi [69 bar] to check
for oil leaks. If there are no leaks, cycle
the drive unit at 10,000 psi [690 bar] and
check again for leaks.
WARNING
Pressurized hydraulic oil
can penetrate the skin and could cause
serious personal injury. Always repair any
oil leaks before using the wrench.
5.4 Preventative Maintenance -
Cassette (Fig. 16, 18, 19 and 20)
• Remove the cassette from the drive unit.
• Remove the screws (K4). Lift and
remove the sideplate (K3).
• Remove the ratchet lever (K8), ratchet
(K7), spring loaded drive shoe (K6), and
compression spring(s) (K5).
The W2000SL Series cassettes use
one compression spring. The W4000SL
Series cassettes use two compression
springs.
• Apply a small amount of Loctite 243
thread sealant to the threaded holes in
the drive unit. See (✽) in Figure 14 for
locations.
• Install two O-rings (G) into the ports on
the base of the swivel post (F).
• Place the swivel post (F) on the drive unit
(H), making sure that hydraulic ports are
aligned. Be careful that O-rings (G) do
not drop out or become pinched or cut.
•
Install the degreased M4 socket head
capscrews (D) and tighten them to
3.7
Ft.lbs [5.1 Nm].
• If the drive unit is equipped with the
optional TSP Pro Series swivel, refer
to the appropriate Enerpac instruction
sheet for additional reassembly
instructions:
L4119 (drive unit models ending in "X")
L2905 (drive unit models NOT ending in "X")
NOTICE Install the couplings (B1 and B3)
and adapter (B2) before installing the
swivel (B) on the swivel post (F). Use a vise
with soft jaws to hold the swivel as
couplings and adapter are installed.
• Apply Loctite 577 sealant to threads on
female coupling (B3) and adapter (B2).
See (◆) in Figure 17 for sealant locations.
B2
B1
B3
B
◆
◆
Fig. 17
◆ Loctite 577
ENGLISH

19
18 (shaded areas). When applying grease,
some overspill into the area above the
slots and runners is permitted. However,
any overspill in this area should be
minimized.
NOTICE Grease overspill into the area
below the slots and runners is NOT
permitted, and must be removed before
continuing with wrench assembly.
• On the ratchet lever (K8), generously
apply molybdenum disulphide grease to
the contact radius and the retract link
slot only. See Figure 19 (shaded areas).
• On the drive shoe (K6), apply
molybdenum disulphide grease to the
rear face only. See Figure 20 (shaded
area).
NOTICE Never apply any grease to the
ratchet lever bore, or to the drive shoe
teeth. Application of grease to these areas
will cause erratic operation, slippage of
drive mechanism and excessive
component wear.
• Disassemble all exposed components
and clean them with a mild solvent. If
desired, gurads can remain attached
to the cylinder locating plate and the
pin retainer assembly can remain
assembled.
• Dry all components.
• Inspect all components for damage.
• To check for free movement, pivot the
ratchet lever (K8) back-and-forth by
hand while it is positioned between the
sideplates, with the slots and runners
engaged.
NOTICE If the ratchet lever does not
move freely, it may be possible to improve
the fit by removing any burrs or flared
edges from the slots and runners, and
smoothing out any imperfections in the
running surfaces. If this does not result in
free movement, a replacement ratchet
lever and sideplates should be installed.
• On each sideplate (K3), apply
molybdenum disulphide grease to the
faces of all slots and runners. See Figure
Fig. 18
W2000SL W4000SL
Lubrication Details
Item (K3) Minimize grease overspill in
area above slots and runners.
NO grease overspill in this area!
✜ molybdenum disulphide grease (shaded areas only)
(✜)(✜)
ENGLISH

20
• Apply a thin coat of molybdenum
disulphide grease to the bore of the
cylinder locating plate and to the top of
the pin retainer assembly. Refer to Figure
16 for molybdenum disulphide grease
locations (✜).
• Reverse the disassembly procedure to
reassemble the tool.
Fig. 19
✜ molybdenum disulphide grease
(shaded areas only)
Fig. 20
Lubrication Details
Item (K8)
Lubricaton Details
Item (K6)
5.5 Full Maintenance - Cassette
(Fig. 16, 18, 19 and 20)
• Disassemble all exposed components
and clean them with a mild solvent.
• Drift out the roll pin (K9) holding the drive
unit retaining pin (K10) in place. Remove
and inspect drive unit retaining pin (K10).
Replace if worn or damaged.
• Inspect all other parts for damage.
• Perform magnetic particle inspection on
the following components:
- Spacer Retaining Pin (K1)
- Pin Retainer (K2)
- Sideplates (K3)
- Drive Shoe (K6)
- Ratchet (K7)
- Ratchet Lever (K8)
- Drive Unit Retaining Pin (K10)
- Fail Safe Retaining Pin (K11)
- Release Lever/Reaction Foot (K12)
• Reinstall drive unit retaining pin (K10)
and roll pin (K9).
WARNING Always reinstall drive unit
retaining pin (K10) if removed. Do not
operate wrench if retaining pin (K10) is
not installed. Failure to reinstall retaining
pin (K10) may allow the drive unit to be
ejected from the cassette during
operation, resulting in possible personal
injury.
• Check for the correct height for the
drive unit retaining pin (K10) and the fail
safe retaining pin (K11). See Figure 21,
dimensions “X” and “Y”.
• Dry all components. Apply a thin coat
of molybdenum disulphide grease (✜)
as indicated in figures 16 and 18. Refer
to Section 5.4 for additional information
about application of molybdenum
disulphide grease.
(✜)
✜ molybdenum disulphide grease
(shaded area only)
(✜)
ENGLISH