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
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
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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.
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5
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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.
Fig. D
Fig. E
• Swing the reaction roller bracket (8) outward, away from center of tool.
3.3 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:
Hose model number Description
THQ-706T
THQ-712T
Two hoses, length
6 m (19.5 feet)
Two hoses, length
12 m (39 feet)
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.
Connect the hoses to the pump. Refer to the pump instruction manual.
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Fig. F
7
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Fig. G
Fig. H
Fig. I
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.
4.2 To set the torque
Adjust the pressure on the pump as necessary to set the torque. Refer to sections
6.3.1 and 6.3.2 for torque setting tables.
4.3.1 To tighten a nut or bolt (fig. G, H, I)
Place the wrench on the ground or on a solid surface, such as a workbench.
Operate the pump in the Retract direction until drive unit is fully retracted and the spanner socket moves fully outward. Stop the pump.
Swing the reaction roller bracket fully outward, away from center of tool.
Position the tool on the nut (bolt) with the clockwise (+) side facing upwards.
Position reaction roller against pipe flange. Note: If a gap between roller and flange is present, position the roller as close to the flange as possible, so that gap is minimal.
Operate the pump in the Advance direction to activate the wrench and begin tightening the nut (bolt).
Stop operation immediately if a gap
appears between the cylinder locating plate and the drive unit.
Never strike the tool with a hammer.
8
PINCH POINT
HAZARD
Keep hands and fingers clear of pinch
point area between spanner and reaction roller. See Fig J.
Keep hands and fingers clear of pinch
point area between pipe flange and reaction roller. See Fig J.
Repeat previous steps as required until nut (bolt) is tightened to the proper torque.
Notes:
Spanner must be repositioned after each wrench cycle by operating the pump in the Retract direction. The tool contains no spring return.
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Fig. J
Fig. K
4.3.2 To loosen a nut or bolt (fig. K, L)
Apply penetrating oil to the threads. Allow the oil to soak.
Reinstall the positioning handle on counter-clockwise (-) side of wrench.
To loosen the nut (bolt), follow steps in section 4.3.1, but with the counter­clockwise (-) side of wrench facing upward.
Repeat steps 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.
Fig. L
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
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Fig. M
Fig. N
5 Maintenance and troubleshooting
5.1 Spanner replacement (Fig M)
Remove drive unit from cassette.
Loosen and remove
• Tap
spanner pin (18) on one end and
remove it from the cassette.
Slide spanner (1) out of cassette housing.
Apply a thin coat of molybdenum disulphide lubricant of the new spanner and to the
pin
at top of spanner.
Slide new spanner (1) into cassette housing. Align hole in spanner with mating holes in sideplates.
• Install
spanner pin (18) through holes.
Before installation, be sure that flat area of pin is aligned with hole in spanner.
Apply a small amount of Loctite 243 to threads of
• Reinstall
set screw (17).
5.2 Preventative maintenance (Fig N & O)
Preventative maintenance can be
carried out by the user. Full maintenance must be carried out by an approved and authorized technician appointed by Enerpac.
Recommended service intervals are:
a) 3 months – Heavy Duty use b) 6 months – Normal use c) 12 months – Infrequent use
set screw (17).
to the sides
spring
set screw
set screw (17).
Fig. O
10
- Non destructive testing must be carried out if the tool has been used under severe conditions.
5.2.1 The roller cassette
Remove drive unit from cassette.
• Remove
the shoulder screws (20). Lift
and remove the sideplate (21).
Remove spanner (1), and
set screw (17) as an assembly.
• Remove
reaction roller bracket pin
spanner pin (18)
(22) and reaction roller bracket (23).
• Remove circlips (24) reaction rollers (25) and
roller pin (26).
Clean all exposed components with a mild solvent.
Inspect all parts for damage.
Dry all components. Apply a thin coat of molybdenum disulphide lubricant
as indicated.
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5.2.2 The hydraulic drive unit
Check tightness of swivel
manifold
post retaining screws (see 5.3.2) and gland.
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 lubricant
as indicated.
5.3 Full maintenance
Note: Refer to the WCR4000 repair
parts sheet for detailed views of components and subassemblies
referenced in sections 5.3.1 and 5.3.2.
5.3.1 The roller cassette
Strip down and clean all exposed components with a mild solvent.
Drift out the cylinder retaining pin, and remove
retaining pin
spring pin holding the
the
.
Inspect all parts for damage.
Perform non destructive testing by
magnetic particle inspection on the following components:
-
Sideplates
- Cylinder locating plate
- Cylinder retaining pin
- Reaction roller bracket and pin
- Reaction rollers and roller pin
Dry all components. Apply a thin coat of molybdenum disulphide lubricant
as indicated.
Retaining Pin Height - Dimension “X”
Metric Imperial
5,00 mm 0.197 inch
Fail Safe Pin Height - Dimension “Y”
Metric Imperial
3,00 mm 0.118 inch
Fig. P
Check retaining pin height (X) and fail safe pin height (Y). Refer to Fig.P.
Reverse the procedure to reassemble the tool.
5.3.2 The hydraulic drive unit
Remove the circlip from the
swivel
manifold block.
• Remove the hydraulic couplings.
• Remove the
swivel manifold block
from the drive unit.
• Remove
swivel manifold post
the retaining screws and the
.
Remove all ‘O’ rings from swivel
manifold post.
Carefully hold the cylinder body to unscrew the cylinder gland.
Hold the two flat sides of the piston rod with a spanner. The rod is located at the spigot.
Remove the button head cap screw from the piston.
Remove the piston rod from the cylinder spigot end.
Remove the piston from the cylinder gland end, using a suitable drift.
11
Clean all exposed components with a
Reverse the procedure to reassemble.
mild solvent.
Inspect all parts for damage.
Perform non destructive testing by
magnetic particle inspection on the
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following components:
- Cylinder
body
- Piston rod
Apply a small amount of Loctite 243 to the threads of the
capscrew
before reassembly.
button head
When reassembling the drive unit make
sure that the piston rod is inserted through the cylinder spigot end.
When reassembling the drive unit
make sure that the piston is inserted through the gland end. Tap the piston gently into place against the piston rod.
Apply a small amount of Loctite 243 to the threads in the drive unit, assemble the swivel
manifold post
and tighten the degreased retaining screws to 5,1 Nm
(3.76 Ft.lbs).
Pressurize the assembled drive unit to max pressure (Advance and Retract), and check for any signs of leakage.
5.4 Troubleshooting
5.4.1 Drive Unit Symptom Cause Remedy
Cylinder does not advance or retract. Quick-connect coupling Replace the coupling. is damaged. Quick connect coupling is Reconnect the hoses not connected. and couplings securely. Dirt in the direction control Disassemble the unit and valve on the pumping unit. clean the valve. Cylinder does not build pressure. Piston seal leaks. Replace the seals. Pump does not build pressure. Adjust the pressure. Pump is defective. Refer to the pump manual. Cylinder leaks. Seal failure. Replace the cylinder seals. Cylinder operates backwards. Connections are reversed.
Reconnect hoses correctly.
5.4.2 Cassette Symptom Cause Remedy
Drive unit operates Spanner broken Replace the spanner. but spanner does not move. or damaged. Note: Top of spanner contains fail-safe area that is designed to break in event of overload. Spanner operation Fasteners loose. Check tightness of all rough or erratic. screws and other fasteners. Parts bent, worn Disassemble and inspect or damaged. roller cassette. Clean, lubricate and replace parts as needed.
12
A
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Fig. Q
C
B
D
E
6 Technical specifications and torque settings
6.1 Capacities and dimensions - Model WCR4000 (fig. Q)
Spanner size range mm 36 - 80 inch 1 Maximum operating pressure bar 690 psi 10,000 Max. torque at 690 bar Nm 5.762 at 10,000 psi Ft.lbs 4,250 Min. torque Nm 576 Ft.lbs 425 Dimensions A mm (inch) 226 (8.9) B mm (inch) 161 (6.3) C mm (inch) 159 (6.25) D mm (inch) 241 (9.5) E mm (inch) 131 (5.2) Weight (cassette only) kg (lbs) 6,2 (13.6) (drive unit only) kg (lbs) 4,0 (8.8) (drive unit and cassette) kg (lbs) 10,2 (22.5) Note: Refer to section 6.2 for spanner weights and dimensions.
7
/16 - 3 1/8
13
6.2 Technical Data - Closed End Spanners (fig. R)
6.2.1 Metric system table
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Spanner (F) (G) (H) Weight Model
mm mm mm kg
W4107CS 36 31,0 30,0 1,9 W4108CS W4110CS W4113CS W4114CS W4200CS W4203CS W4206CS W4209CS W4212CS W4215CS W4302CS
38 32,8 30,0 2,1 41 32,8 30,0 2,2 46 35,6 30,0 2,1 48 38,4 30,0 2,1 50 38,4 30,0 2,2 55 41,2 30,0 2,1 60 45,0 30,0 2,2 65 46,8 30,0 2,1 70 49,6 30,0 2,2 75 52,1 30,0 2,1 80 55,4 30,0 2,2
6.2.2 Imperial system table
Spanner (F) (G) (H) Weight Model
inch inch inch lbs
W4107CS 1 7/16 1.22 1.18 4.0 W4108CS 1 1/2 1.26 1.18 4.7 W4110CS 1 5/8 1.26 1.18 4.7 W4113CS 1 13/16 1.38 1.18 4.6 W4114CS 1 7/8 1.50 1.18 4.6 W4200CS 2 1.50 1.18 4.8 W4203CS 2 3/16 1.61 1.18 4.5 W4206CS 2 3/8 1.81 1.18 4.9 W4209CS 2 9/16 1.81 1.18 4.5 W4212CS 2 3/4 1.93 1.18 4.9 W4215CS 2 15/16 2.05 1.18 4.5 W4302CS 3 1/8 2.17 1.18 4.9
G
Fig. R
F
H
14
6.3 Torque settings
To set the torque, adjust the pump pressure according to the following calculation:
Pump pressure = Torque / Torque factor
Measurement system Torque factor
Metric 8,351 Imperial 0.425
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6.3.1 Metric system pressure/torque
table - Model
WCR4000
Pump pressure (bar) Torque (Nm)
69 576 124 1.036
179 1.495 207 1.729 234 1.954 262 2.188 290 2.422 317 2.647 345 2.881 372 3.107 400 3.340 428 3.574 455 3.800 483 4.034 510 4.259 538 4.493 566 4.727 593 4.952 621 5.186 648 5.411
690 5.762
6.3.2 Imperial system pressure/torque table - Model WCR4000
Pump pressure (psi) Torque (Ft.lbs)
1,000 425 1,800 765 2,600 1,105 3,000 1,275 3,400 1,445 3,800 1,615 4,200 1,785 4,600 1,955 5,000 2,125 5,400 2,295 5,800 2,465 6,200 2,635 6,600 2,805 7,000 2,975 7,400 3,145 7,800 3,315 8,200 3,485 8,600 3,655 9,000 3,825 9,400 3,995
10,000 4,250
15
7 Replacement parts and
recommended tools
7.2 Recommended
maintenance and repairs
tools for performing
7.1 To order replacement parts
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For replacement parts information,
refer to the Enerpac repair parts sheet for your wrench model. Repair parts sheets are available on the internet at www.enerpac.com.
Have the following information ready
when ordering replacement parts:
- Wrench model and serial numbers (for both drive unit and cassette).
- Approximate date of purchase.
- Part number and description of each part being ordered.
1 7/8" A/F spanner – 1 3/4" A/F spanner – 1 5/8" A/F spanner – 1 Circlip pliers – 1 Seal extraction tool – 1 ø 4 mm x 5 mm LG x 25 mm PCD
pin spanner – 1 6 mm A/F Allen key – 1 4 mm A/F Allen key – 1 3 mm A/F Allen key – 1 2,5 mm A/F Allen key – 1 Copper hammer – 1 3 mm terminal screwdriver
Notes: A/F = Across Flats PCD = Pitch Circle Diameter
16
NOTES:
17
NOTES:
18
NOTES:
19
Australia and New Zealand
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Luiz Lawrie Reid, 548
09930-760
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Russia
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98090 91 F +7 495 98090 92 sales-ru@enerpac.com
and Taiwan
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Enerpac Integrated Solutions B.V.
Opaalstraat 44 7554 TS Hengelo P.O. Box 421 7550 AK Hengelo The Netherlands T +31 74 242 20 45 F +31 74 243 03 38 integratedsolutions@enerpac.com
South Africa and other English speaking African countries
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United Kingdom and Ireland
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All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them.
For the location of your nearest authorized Enerpac Service Center, visit us at www.enerpac.com
Enerpac Worldwide Locations e-mail: info@enerpac.com internet: www.enerpac.com
012313
Southeast Asia, Hong Kong
© Enerpac 09-2013 - All contents subject to change without notice.
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