Enerpac W35000 User Manual

Instruction Sheet

W22000 Series
W35000 Series
Hydraulic Torque Wrench

L3009

English (GB) Rev. C 12/2011

2

Instruction Sheet Torque Wrench
W22000 Series
W35000 Series

Index

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3 Assembly and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Maintenance and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 Technical specifications - W22000 Series . . . . . . . . . . . . . . . . . . . . . 13

7 Technical specifications - W35000 Series . . . . . . . . . . . . . . . . . . . . . 19

8 Replacement parts and recommended tools . . . . . . . . . . . . . . . . . . 24

3

1 Introduction

Overview
The Enerpac W-Series hydraulic torque
wrench is designed for controlled
tightening and loosening of fasteners
in industrial bolting applications. Its
low profile cassette, compact drive
unit and
the W-Series ideal for use in locations
where workspace is limited.
Interchangeable W-Series cassettes
are available in a large assortment of
both metric and imperial 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 models are
available.

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

• All Enerpac products are guaranteed

Any misuse or alteration invalidates the
warranty.

• Observe all instructions as

• Replace any parts with Enerpac

integrated reaction foot make

for the purpose for which is intended.

against defects in workmanship and
materials for as long as you own
them.

communicated in this manual.

spare parts only.

CE Declaration of conformity

Enerpac declares that the W22000 and
W35000 Series torque wrenches meet
the applicable standards and directives
issued by the European Community.
For a detailed list refer to the separate
certification sheet.

2 Safety

Be aware that the operator is fully
responsible during the operation of
this tool. Enerpac is not responsible for
damage or injury caused by misuse of
this tool. Under some circumstances,
additional safety precautions beyond
those described in this manual may be
required. Contact Enerpac immediately
if a potentially hazardous situation
arises.

Read this manual carefully and
observe all safety precautions.

- Make sure you have 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 at least
18 years of age.

- 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 co-workers.

- Make sure your workplace is safe.

- Do not place any part of the body
between the reaction foot and the
reaction point.

- Do not place any objects between
the reaction foot and the reaction
point. Keep the hoses away from the
reaction points.

- Do not stand in the line of movement

4

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.

- Tightening and loosening nuts and
bolts involves little visible movement.
The pressure and loads, however
are extreme. Keep your hands away
from the fastener being loosened or
tightened.

- Make sure that the spanner used to
keep the nut or bolt on the opposite
end is secured.

- Always use Enerpac pumps and
hoses.

- Make sure appropriate guards are
always securely in position and free
from damage.

- Maximum pressure is 690 bar (10,000
psi). Never apply more pressure
to any tool or accessory than the
maximum allowable pressure. Refer
to the technical data tables for
maximum pressure setting.

- Make sure that the ratchet size
corresponds to the size of the
fastener being loosened or tightened.
Failure to do so can result in the tool
becoming unstable and can lead to
catastrophic failure of the tool.

- Do not abuse or overstress the hoses
in any way. Do not bend the hoses
excessively.

- Never carry the tool by its hoses.

- Always use Enerpac spare parts.

- Always position the tool for maximum
stability. Make sure reaction points
are adequate for the forces at work
during operation of the tool.

- Be aware that a nut or bolt that
breaks off during operation of the tool
will become a high velocity projectile.

- Make sure the reaction point is of
a suitable shape. For example use
an adjacent nut or bolt as a reaction
point.

- When the hex ratchet is placed on the
nut or bolt a gap may exist between
the reaction foot and the reaction
plate. When the tool is operated the
reaction foot and point will make
forceful contact. Always make sure
the tool is stable.

- Provide adequate support in vertical
and inverted applications.

- The maximum torque output of the
tool must always exceed the torque
required to loosen or tighten the nut
or bolt.

- The torque required to loosen a nut is
variable and may exceed the torque
capacity of the tool. Never operate
the tool at above 75 percent of tool
maximum torque when loosening a
nut or bolt (see section 4.3.2).

- Never operate the tool with a
hydraulic supply connection to
the advance side only as this may
damage the internal parts.

- If the wrench is dropped from a
height, have the tool inspected before
you operate it again.

- In severe conditions the tool must
be cleaned and lubricated more
frequently (see section 5).

- Check that the swivel post screws
(see 5.2.1) and gland are tight prior to
use.

- If oil leakage is evident, replace seals
accordingly (see section 5).

- Stop operation immediately if a gap
appears between the cylinder locating
plate and the drive unit. Have the tool
inspected and serviced before you
operate it again.

- Make sure to minimize torsional and
bending stresses in the tool, the hex
ratchet and any accessories.

- Do not strike the tool with a hammer
while under a full load. This will
invalidate the product warranty.

- Always observe the maintenance
instructions.

5

3 Assembly and adjustments

3.1 Overview and features
(fig. A or B)

1 Hexagon ratchet
2 Cassette
3A Swivel coupling or
3B TSP-Pro swivel coupling (optional)
4 Advance hose connection
5 Return hose connection
6 Hydraulic drive unit
7 Cassette release lever
8 Reaction foot

Fig. A

Fig. B

Fig. C

3.2 To attach the positioning handle

(fig. C)

• Secure the positioning handle (9) with
eye-bolt (10). Tighten hand tight.

3.3 Changing the cassette

Make sure to depressurize and
disconnect the tool from the
hydraulic supply first.

3.3.1 To remove cassette (fig. D & E)

• Make sure the piston is fully
retracted.

• Place the tool on a workbench or
support it using a hoist.

Hydraulic drive unit will disengage
from cassette in the following
steps. Be sure that cassette is
supported so it does not drop.

• Pull the cassette release lever (7)
outwards.

• Remove the hydraulic drive unit (6)
from the cassette (2).

3.3.2 To attach cassette (fig. D & E)

• Make sure the retract link (11) aligns
with the slot (13) in the crank. Rotate
the piston rod if necessary.

• Pull the release lever (7) outwards.

• Push the spigot (12) into the cylinder
locating plate (14).

6

Fig. D

• Push the release lever (7) back into
the cassette (2). Make sure the ball
detent clicks into place.

Do not operate the tool if the
cassette release lever is not fully
closed.

3.4 To connect the hoses (fig. F)

Make sure all accessories meet
the pressure requirements.
Make sure the quick connect
couplings are securely attached
before operating the tool.

The tool is fitted with male and female
quick-connect couplings. Use Enerpac
twin safety hoses only. Refer to the
table below:

Fig. E

Fig. F

Enerpac hose

model number

THQ-706T

THQ-712T

Description

Two hoses, 6 m

(19.5 feet) long

Two hoses, 12 m

(39 feet) long

• Remove the hose dust caps.

• Connect the hose with the female
coupling (15) to the advance
coupling (4).

• Pull the sleeve on the female
coupling of the hose over the
advance coupling.

• Tighten the sleeve.

• Connect the hose with the male
coupling (16) into the return
coupling (5).

• Pull the sleeve on the return coupling
over the male coupling of the hose.

• Tighten the sleeve.

• Fit the hoses to the pump.
Refer to the pump instruction
manual.

7

Fig. G

Fig. H

4 Operation

4.1 Prior to operation

- Make sure the nut or bolt to be
fastened is clean and free of dust.

- Make sure the nut or bolt runs
correctly on the thread.

- Make sure that the threads and the
bearing surface are liberally coated
with the correct lubricant or anti­seizure compound.

- Make sure that the spanner used to
keep the nut or bolt on the opposite
end in place, is of the correct size
and that there is an adequate
abutment surface. Ensure that the
spanner is secured.

- Contact Enerpac if a suitable
reaction point is not available.

4.2 To set the torque

Adjust the pressure on the pump as
necessary to set the torque.

4.3.1 To tighten a nut or bolt

(fig. G & H)

• 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.

• Stop the pump immediately after
work has finished.

Stop operation immediately if a
gap appears between the cylinder
locating plate and the drive unit.
Do not strike the tool with a
hammer while under a full load.

8

Fig. I

Fig. J

4.3.2 To loosen a nut or bolt (fig. I & J)

• 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 (bolt) is loose.

If the nut or bolt will be re-used
avoid excess load when
loosening.

- Be aware that when loosening a nut
or bolt more torque is usually required
than when tightening.

- Humidity corrosion (rust) requires
up to twice the torque required for
tightening.

- Sea water and chemical corrosion
requires up to two and a half times
the torque required for tightening.

- Heat corrosion requires up to
three times the torque required for
tightening.

Be aware that when loosening a
nut or bolt shock loading can
occur. Do not apply more than
75% of the wrench’s maximum
torque when loosening nuts or
bolts.

9