Enerpac WCR User Manual

Instruction Sheet

WCR4000 Roller Cassette

L4021

English (GB) Rev. B 09/2013

2

Instruction Sheet Roller Cassette
WCR4000

ENGLISH

Index

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

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

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

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

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

6 Technical specifications and torque settings . . . . . . . . . . . . . . . . . . . . 13

7 Replacement parts and recommended tools . . . . . . . . . . . . . . . . . . . . 16

3

1 Introduction

2 Safety

Overview

The Enerpac WCR4000 roller cassette
provides controlled tightening and loosening

ENGLISH

of fasteners on pipe flanges. It is designed
for use in confined spaces where an ordinary
hydraulic torque wrench might not fit.
The roller cassette is powered by the
Enerpac W4000 Series drive unit and a
compatible 690 bar (10,000 psi) torque
wrench pump.
Spanners are available from Enerpac in a
wide range of bolt sizes typically used on
API flanges. The spanners can be changed
quickly using standard hand tools.

Note: Drive unit, pump and spanners are
sold separately and are not included with
the roller cassette.

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.

• Replace any parts with Enerpac spare
parts only.

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 requirements 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 a
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,
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 roller and the
pipe flange.

- Do not place any objects between
the reaction roller and the pipe flange.
Keep the hoses away from this area
to prevent them from becoming
pinched or crushed.

footwear and gloves (at a

4

- 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.

- 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
retain 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

pressure/torque tables for pressure/

torque settings. (see sections 6.3.1
and 6.3.2)

- Make sure that the spanner size
corresponds to the hex 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 the pipe flange is 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

may become a high velocity projectile.

- When the spanner is placed on the

nut or bolt a gap may exist between
the reaction roller and the pipe flange.
When the tool is operated the reaction
roller will make forceful contact with
the pipe flange. 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. Therefore never
operate the tool at maximum or close
to maximum capacity when loosening
a nut or bolt.

- 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

manifold post

screws (see section 5.3.2) and gland
are tight prior to use.

- If oil leakage is evident, replace seals
accordingly (see section 5.3.2).

- 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
spanner and any accessories.

- Do not strike the tool with a hammer.
This will invalidate the product
warranty.

- Always observe the maintenance
instructions.

ENGLISH

5

ENGLISH

Fig. A

Fig. B

3 Assembly and adjustments

3.1 Overview and features (fig. A or B)

1 Spanner
2 Roller Cassette
3A Swivel
3B TSP-Pro Swivel
4 Advance hose connection
5 Return hose connection
6 Hydraulic drive unit
7 Cassette release lever
8 Reaction roller bracket and rollers
9 Positioning handle
10 Thumb screw

3.2.1 To attach the positioning handle

• Secure the positioning handle (9) with

Note: handle can be installed on

3.2.2 To remove the cassette (fig. D)

• Make sure the piston is fully retracted.

• Hold the tool with the drive unit

• Swing the

• Pull the release lever (7) outwards.

• Remove the cassette (2) from the

manifold (standard)

manifold (optional)

(fig. C)

thumb screw (10). Tighten hand tight.

either side of wrench (as needed).

pointing upwards.

reaction roller bracket (8)

inward, toward center of tool.

hydraulic drive unit (6).

Fig. C

6

3.2.3 To attach the cassette (fig. D and E)

• Make sure the retract link (11) aligns
with the slot (12) in the spanner (1).
Rotate the piston rod if necessary.

• Pull the release lever (7) outwards.

• Push the spigot (13) through the hole
in the cylinder locating plate (14).

• 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.