Enerpac HMT1500, HSQ1500, HSQ3500 Operation And Maintenance Manual
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Operation and Maintenance Manual
Enerpac HMT
HMT Modular Tool
Document Number: L4478
Document Revision: A
Document Revision Date: 25-AUG-2020
Document Language: ENGLISH EN
To reduce the risk of injury, user must read and understand this document before use.
ABOUT US
Enerpac is a global market leader in high pressure hydraulic tools, controlled force products, portable machining, on-site services and solutions for precise positioning of heavy loads. As a leading innovator with a
110-year legacy, Enerpac has helped move and maintain some of the largest structures on earth. When safety and precision matters, elite professionals in industries such as aerospace, infrastructure, manufacturing, mining, oil & gas and power generation rely on Enerpac for quality tools, services and solutions. For additional information, visit www.enerpac.com. www.facebook.com/enerpac www.youtube.com/enerpac www.linkedin.com/company/enerpac www.twitter.com/enerpac
WARRANTY
Refer to the Enerpac Global Warranty document for terms and conditions of the product warranty. Such warranty information can be found at www.enerpac.com.
NAMEPLATE
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Tool
Name
Tool
Number
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Tool Serial Number
Pinch Point
Warning
3D
Barcode
L4478_a 1
2
Contents
1. SAFETY ..........................................................................................................................................................3
1.1 SAFETY PRECAUTIONS ......................................................................................................................3
1.2 ATEX SAFETY PRECAUTIONS .............................................................................................................5
2. COMPLIANCE STATEMENT(S) ....................................................................................................................6
2.1 EU DECLARATION OF INCORPORATION ........................................................................................6
2.2 ATEX COMPLIANCE STATEMENT .......................................................................................................6
3. FEATURES & COMPONENTS ......................................................................................................................7
3.1 FEATURE DIAGRAM .............................................................................................................................7
3.2 FEATURE DESCRIPTION ......................................................................................................................9
3.3 HOSE CONNECTION ..........................................................................................................................11
4. TECHNICAL PRODUCT DATA ....................................................................................................................12
4.1 HMT WITH HLP CASSETTE DIMENSIONAL CALLOUT ART ...........................................................12
4.2 HMT WITH HLP CASSETTE DIMENSIONAL TABLE.........................................................................12
4.3 HMT WITH HSQ CASSETTE DIMENSIONAL CALLOUT ART ..........................................................13
4.4 HMT WITH HSQ CASSETTE DIMENSIONAL TABLE ........................................................................13
5. OPERATION .................................................................................................................................................14
5.1 INITIAL SETUP ....................................................................................................................................14
5.2 OPERATING HMT WITH HLP CASSETTE ASSEMBLY .....................................................................15
5.3 OPERATING HMT WITH HSQ CASSETTE ASSEMBLY.....................................................................16
6. STORAGE ....................................................................................................................................................16
6.1 RECOMMENDED STORAGE ..............................................................................................................16
7. MAINTENANCE ...........................................................................................................................................17
7.1 GENERAL MAINTENANCE .................................................................................................................17
7.2 PREVENTATIVE MAINTENANCE ......................................................................................................17
7.3 FULL MAINTENANCE .........................................................................................................................17
8. PARTS LIST .................................................................................................................................................24
9. TROUBLESHOOTING .................................................................................................................................38
L4478_a
1. 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.
1.1 Safety Precautions
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 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.
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.
• 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.
messages
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 that follow this symbol to avoid the possibility of death or serious injury.
• 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.
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.
• 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.
DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious personal injury.
• 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.
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.
• Maximum allowable operating pressure for the
HMT-Series torque wrench is 10,000 psi [690 bar].
Do not exceed this pressure setting.
NOTICE 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.
• 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 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.
L4478_a 3
• 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 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.
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.
• 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 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.
• 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.
4 L4478_a
1.2 ATEX Safety Precautions
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 HMT-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 HMT-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].
NOTICE To help prevent a mechanical spark hazard, no components containing a magnesium content greater than 7.5 percent have been used in the HMT-
Series torque wrench (in accordance with standard EN
13463-1).
• Take extreme care to prevent the HMT-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 HMT-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.
• Enerpac has designed and constructed the HMT-
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.
L4478_a 5
2. Compliance Statement(s)
2.1 EU Declaration of Incorporation
•HMT1500 •HMT3500 •HMT7500
These tools conform with the requirements for CE.
2.2 ATEX Compliance Statement
In addition to the CE mark, the Enerpac HMT-Series torque wrenches carry the ATEX mark and classification:
● HMT1500 ● HMT3500 ● HMT7500
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 Incorporation is enclosed with each shipment of this product.
Ex II 2 G c T6
This classification indicates that the tool is appropriate for use in a potentially explosive atmosphere.
The testing standards applicable to the HMT-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 HMT-Series torque wrenches in hazardous environments.
6 L4478_a
3. Features & Components
3.1 Feature Diagram
1. Swivel Adaptor +
Hose Connections
2. Wrench Body
3. Fixed Pin
4. Rod End
5. Bottom Retaining Pin
6. Lanyard
7. Handle
8. Back Cap
7 7
2 2
Figure 1: Major features and components of HMT Drive Unit
1. Front Spacer
2. Ratchet Cassette Side Plate
3. Drive Plate
4. Hex Ratchet
5. Drive Pin
6. Bottom Retaining Pin
(part of the HMT Drive
Unit Assembly)
6
5
6 5
L4478_a
4
4
Figure 2: Major features and components of HMT HLP Low Profile Cassette
7
8
1. Square Drive Cassette Body
2. Drive Pin
3. Body Spacer
4. Drive Plate
5. Reaction Arm Spline
6. Reaction Arm Set Screw
7. Square Drive
8. Reaction Arm
9. Retaining Ring
10. Link Pin Assembly
11. Link Pin Assembly Lanyard
12. Square Drive Socket Attachment
Figure 3: Major features and components of HMT HSQ Square Drive Cassette
L4478_a
3.2 Feature Description
3.2.1 Assembling HLP/ HSQ Cassette
Assemblies onto HMT Drive Unit
The HLP and HSQ cassette assemblies each include a hook feature as part of the body assembly, this is inserted around the top retaining pin of the drive. The cassette assembly rest along the base of drive unit body.
At this point, the bottom retaining pin holes in the drive unit body and cassette assembly will align, allowing the bottom retaining pin to be inserted fully to secure the two together.
3.2.2 Engaging HMT Drive Unit Rod End with HLP/ HSQ Cassette Drive Plate
Assembly
When assembling the HLP or HSQ Cassette onto the
HMT drive unit body ensure that the rod end of the drive unit is fully engaged with the drive pin in the drive plate of the cassette assembly by rotating the ratchet or square drive 1/4 turn back and forth a number of times by hand until engagement is confirmed.
CAUTION
Failure to ensure correct engagement of the wrench body and drive plate assembly drive pin prior to operation will damage the rod end. Resulting damage will not be covered under warranty.
Figure 4: Connecting HLP Cassette and HMT Drive
Unit
3.2.3 Using Extended Reaction Arm/
Reaction Paddle with the HMT with HLP
Cassette
To use the HMT with the HLP Cassette, a suitable reaction surface must be available.
If bolt spacing is such that the reaction surface of the wrench does not reach a suitable reaction surface such as an adjacent bolt, use the extended reaction arm or reaction paddle as depicted. This will allow reaction to be taken against the side of the flange.
To attach the reaction paddle or extended reaction arm, remove the standard bottom retaining pin, align the holes of the reaction paddle or extended reaction arm with that of the reaction surface of the wrench, insert the long retraining pin to secure.
Ensure the reaction paddle or extended reaction arm extends in the appropriate direction: right for tightening; left for loosening.
Figure 5: Connecting HSQ Cassette and HMTDrive
Unit
Figure 6: Installing Reaction Paddle
L4478_a
Figure 7: Installing Extended Reaction Arm
9
3.2.4 Using HSQ Reaction Arm
The HMT with the HSQ Cassette assembly comes with a reaction arm that is assembled directly onto the square drive.
Slide the square drive reaction arm over the reaction arm spline and secured using a socket screw. This is designed to allow the square drive to move as required while the reaction stay in place, as shown in Figure 8.
Ensure the reaction arm extends in the appropriate direction: right for tightening; left for loosening.
CAUTION
Failure to ensure correct engagement of the wrench body and drive plate assembly drive pin prior to operation will damage the rod end. Resulting damage will not be covered under warranty.
3.2.5 Selecting HSQ Cassette Direction
The following diagram illustrates the direction the square drive should face for loosening and tightening of a standard right hand fastener:
• For tightening bolts, install the square drive in the location shown in Figure 9.
• For loosening bolts, install the square drive on the opposite side of the wrench.
3.2.6 Attaching Handle
Secure the positioning handle with thumb screw or eyebolt. Handle can be installed on either side of wrench body (as needed).
Ensure that handle or eyebolt is correctly secured in place before lifting the wrench.
Figure 8: Installing Square Drive Reaction Arm
Left for loosening Right for tightening
Figure 9: Drive Directions for Loosening/ Tightening
Figure 10: Attaching Handle
10 L4478_a
3.3 Hose Connection
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 torque wrench and hydraulic pump are connected by a 10,000 psi [690 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.
CAUTION
NEVER use an even number of hydraulic twin 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 11: Hose Connection
L4478_a 11
4. Technical Product Data
4.1 HMT with HLP Cassette Dimensional Callout Art
A
E
F
B
C
D
4.2 HMT with HLP Cassette Dimensional Table
Maximum Operating
Pressure
Minimum Torque
Maximum Torque
Weight
Dimensions
Cassette
HMT
A
B
C
D
E
F psi bar lbf.ft
Nm lbf.ft
Nm
HMT1500
10,000
690
154
209
1,541
2,089 lbs kg
4.41
2.0
lbs 2.2
kg inch [mm]
1.0
7.23 [183.72] inch [mm] 1 1 /
16
" - 2 1 /
4
" [26 - 57] inch [mm] 0.38 [9.75] inch [mm] 1.2 [31.5] inch [mm] 1.94 [49.40] inch [mm] 4.01 [102]
Model Number
HMT3500
10,000
690
354
480
3,543
4,804
8.82 - 11.02
4.0 - 5.0
3.97
1.8
5.79 [147.12]
1 3 /
8
" - 3 1 /
8
" [35 - 80]
0.50 [12.75]
1.7 [42.0]
2.58 [65.50]
5.35 [136]
HMT7500
10,000
690
756
1,025
7,562
10,252
17.63 - 19.84
8.0 - 9.0
7.05
3.2
12.16 [308.80]
2 3 /
16
" - 3 15 /
16
" [55 - 100]
0.64 [16.30]
2.1 [52.6]
3.23[82]
6.70 [170.11]
12 L4478_a
4.3 HMT with HSQ Cassette Dimensional Callout Art
A
B
D
F
E
G
4.4 HMT with HSQ Cassette Dimensional Table
Square Drive
Maximum Operating
Pressure
Minimum Torque
Maximum Torque
Weight
Dimensions
HSQ
HMT
A
B
C
D
E
F
G lbs kg inch [mm] inch [mm] inch [mm] inch [mm] inch [mm] inch [mm] inch [mm] psi bar lbf.ft
Nm lbf.ft
Nm lbs kg
HSQ1500
3/4"
10,000
690
154
209
1,541
2,089
5.95
2.7
2.2
1.0
7.28 [184.83]
6.45 [163.94]
2.34 [49.50]
1.19 [30.20]
2.36 [60]
4.33 [110]
3.36 [85.37]
Model Number
HSQ3500
1"
10,000
690
354
480
3,543
4,804
9.04
4.1
3.97
1.8
8.36 [212.25]
8.13 [206.60]
2.58 [65.50]
1.52 [38.50]
3.07 [78]
5.83 [148]
4.36 [110.80]
C
HSQ7500
1 1/2"
10,000
690
756
1,025
7,562
10,252
18.08
8.2
7.05
3.2
9.64 [245]
10.08 [256.06]
3.15 [80]
1.99 [50.50]
4.33 [110]
8.27 [210]
6.40 [162.65]
L4478_a 13
5. Operation
5.1 Initial Setup
5.1.1 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.
5.1.2 Inspection 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 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.
Figure 12: Using the Pump
14 L4478_a
5.2 Operating HMT with HLP
Cassette Assembly
The position of the tool relative to the nut determines whether the action will tighten or loosen the nut. The power stroke of the piston assembly will always turn the ratchet hex toward the front spacer.
1. Place the ratchet hex on the nut. Make certain it is the correct size for the nut and that it fully engages the nut.
2. Position the reaction surface of the wrench against a suitable reaction surface such as an adjacent nut, flange or solid system component. Make certain that there is clearance for the hoses, and swivel coupling assembly. DO NOT allow the tool to react against the hoses, or swivel coupling assembly.
If required attach the extended reaction arm or reaction paddle, as depicted in Figure 13/ 14, to allow reaction against the side of the flange.
3. Turn the pump on and set up the pre-set pressure for the correct torque. Use the remote control advance button to advance the piston assembly.
CAUTION
Ensure that the rod end has engaged with the drive pin in the HLP cassette assembly prior to use.
4. When the HLP cassette assembly is connected to the nut and the wrench started, the reaction surface of the wrench will move against the contact point and the nut will begin to turn. Once the piston reaches the end of its stroke, the pressure will rise rapidly. On the pump use the controls to retract the tool. There is usually a series of audible clicks as the tool retracts.
5. Continue this cycling operation of advance and retract until the nut is no longer turning and the pump gauge reaches the pre-set pressure.
6. Once the nut stops rotating, cycle the tool one last time to ensure final torque has been achieved.
Figure 13: Position HMT with HLP Cassette with a suitable reaction point
Figure 14: Using reaction paddle
L4478_a
Figure 15: Using extended reaction arm
15
5.3 Operating HMT with HSQ
Cassette Assembly
The position of the tool relative to the nut determines whether the action will tighten or loosen the nut. The power stroke of the piston assembly will always turn the square drive toward the body spacer.
1. Before using the HMT drive unit and HSQ cassette assembly, cycle the wrench two or three times to ensure that the link is inserted correctly.
2. Select correct socket for bolt to be loosened / tightened.
3. Ensure the reaction arm contacts a suitable reaction point at a 90° angle from the square drive, as per the following image;
4. After having turned the pump on, input the preset pressure for the correct torque, and using the remote control advance the piston assembly.
CAUTION to use.
Ensure that the rod end has engaged with the drive pin in the square drive cassette assembly prior
5. When the socket is connected to the nut and the wrench started, the reaction surface of the wrench will move against the contact point and the nut will begin to turn. Once the piston reaches the end of its stroke, the pressure will rise rapidly. On the pump use the controls to retract the tool. There is usually a series of audible clicks as the tool retracts.
6. Continue this cycling operation of advance and retract until the socket is no longer turning and the pump gauge reaches the pre-set pressure.
Figure 16: Position HMT with HSQ Cassette with a suitable reaction point
7. Once the nut stops rotating, cycle the tool one last time to ensure final torque has been achieved.
8. To reverse the torque wrench direction, release the drive retainer and pull out the square drive. Move the square drive to the opposite side and reinsert retainer.
6. Storage
6.1 Recommended Storage
Enerpac tools should be stored in a cool, dry place.
Tools should always be cleaned, serviced and lubricated prior to storage. Ensure that tools are stored in their designated packing cases.
16 L4478_a
7. Maintenance
7.1 General Maintenance
Preventative maintenance can be performed by the user.
Recommended service intervals are:
• 3 months – Heavy Duty use
• 6 months – Normal use
• 12 months – Infrequent use
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 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 and for the accuracy assurance pawl. These springs can be replaced if necessary.
3. If the piston rod requires disassembly, it is recommended that the piston rod 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.
6. All structural parts on the tools should be inspected at least once a year to determine if there are any cracks, chips, or deformities.
7. Non destructive testing must be carried out if the tool has been used under severe conditions.
Full maintenance must be performed only by an Enerpac authorized service center or a qualified and experienced technician.
7.2 Preventative Maintenance
1. Check tightness of swivel assembly retaining screws (12) and drive unit body back cap screws
(10) (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.
7.3 Full Maintenance
7.3.1 Hydraulic Swivel Assembly
Disassembly of Swivel Post and Swivel Assembly
Attachment (Fig 17 + Fig.18)
• Remove the circlip (A) from the top of the swivel post (E).
• Using a pair of flat blade screwdrivers, gently pry the swivel assembly (B) from the swivel post (E).
• Remove O-ring (D) from the swivel post (E).
• Remove the socket head capscrews (C) and the swivel post (E).
• Remove O-rings (F) from the swivel post hydraulic ports.
• Place the swivel assembly in a vise with soft jaws.
Remove the hydraulic couplings (B1, B2 and B3) from the swivel assembly (B).
Hydraulic Swivel and Swivel Post Reassembly and
Reinstallation
Hydraulic Fittings:
NOTICE If removed, reinstall 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 Fig. 25 for locations.
• 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 wrench.
L4478_a 17
Swivel Post:
• Apply a small amount of Loctite 243 thread sealant to the threaded mounting holes in the wrench housing. See Fig. 11 for locations.
• Install two new O-rings (F) into the ports on the base of the swivel post (E).
• Place the swivel post (E) onto the wrench (G), making sure that hydraulic ports are aligned. Be careful that O-rings (F) do not drop out or become pinched or cut.
• • Install the degreased socket head capscrews (D) and tighten to 3.7 Ft.lbs [5.1 Nm].
Swivel Assembly:
• Install a new O-rings (D) into the grooves on the swivel post (E).
• Coat O-rings (D) with a small amount of silicone grease. Then, carefully slide the swivel assembly
(B) onto the swivel post (E).
• Reinstall the circlip retainer ring (A).
• Perform hydraulic pressure testing before placing the wrench into service. Refer to the procedure in
Section 7.2.6
7.3.2 HMT Drive Unit (Fig. 19)
• Disassembly
• Firmly hold the drive unit body (1). Remove bottom retaining pin (11) and ball end screw (9) from the drive unit, separate cassette assembly from the drive unit.
• Unscrew the socket button head cap (18) from the back cap (2) and remove the bottom retaining pin lanyard (17).
• Remove the retaining rings (11) and top retaining pin (6).
• Unscrew the eight socket head cap screws (10) and remove the back cap (2) and back cap o-ring
(15).
• Unscrew and remove the rod end (4) from the front of the drive unit body, holding the Piston Rod (3) with a spanner to prevent rotation.
• Remove piston rod (3) and seals, O-rings and bush
(13, 16, 14, 5) from the drive unit body.
• Check and remove any remaining seals, O-rings or bush from the drive unit body.
• Remove grub screw (8) and O-ring (20).
• Clean all exposed components with a mild solvent.
• Inspect all parts for damage.
✤ Apply silicone grease to O-rings.
A
✽ Apply Loctite 243
Thread Sealant
(inside bolt holes)
Tighten to Torque Value of 5.9 Ft.lbs [8 Nm]
B
✤D
E
✽
✤F
✽
✽
✴ Apply Loctite 577 Thread Sealant (thread of B2 and B3)
B
�
B2
B1
�
D ✤
C �
Figure 17: Swivel Post and Swivel Assembly
B3
G
Figure 18: Exploded Swivel Assembly
18 L4478_a
• Reassembly and Installation
NOTICE In the following steps, coat all O-rings and seals with silicone grease before installation.
NOTICE Do not use excessive force when installing the piston rod (3) in the following steps. Excessive force may cause damage to these component and also may damage the sealing faces within the wrench.
• Insert the O-ring (20) and grub screw (8) into the relief shaft.
NOTE: Ensure the grub screw (8) and O-ring (20) have been installed after Loctite 577 has been applied. Loctite must be fully cured before testing.
• Fit bush (5) and rod end seal (14) into the drive unit body piston shaft (1)
• Insert the piston O-ring (16) into the lower groove on the piston rod (3) followed by the piston cup seal (13) into the upper groove. Insert the piston rod (3) into the drive unit body (1).
• Apply threadlock to the Rod End (4) threads and install into the Piston Rod (3), holding the Piston
Rod with a spanner to prevent rotation.
• Install the back cap thread O-ring (15) into the groove in the back cap body (2).
• Attach the back cap (2), and secure with the eight socket head cap screws after applying Loctite 243
Thread Sealant (10).
Tighten the socket head cap screws to the following Torque values:
ο HMT1500 : 6 Ft/lbs [8 Nm]
ο HMT3500 : 14 Ft/lbs [19 Nm]
ο HMT7500 : 30 Ft/lbs [41 Nm]
• Place the bottom retaining pin lanyard (17) onto the back cap and secure with the socket button head cap (18).
• Fit the top retaining pin (6) and retaining ring (11).
• If removed, reinstall the hydraulic swivel and swivel post. Refer to Section 7.2.1.
• Assembly with the appropriate cassette assembly, secured with bottom retaining pin (11) and ball end screw (9); and perform hydraulic pressure testing before placing the wrench into service. Refer to the procedure in Section 7.2.6.
10 ✽⁂
17
18
2
15 ✫
13 ✫
16 ✫
8 ✴
20 ✫
✫ Apply ISO 10 grade oil to O-rings.
✽ Apply Loctite 243 Thread Sealant
Apply Loctite 577 Thread Sealant
Apply Threadlock
12
1
3
�
14 ✫
5 ✫
11
6
4
� �
9
19
⁂• See 7.3.2, Reassembly and Installation for Torque Values.
Figure 19: Exploded HMT
L4478_a
7
19
7.3.3 HMT HLP Cassette Assembly -
Disassemblyand Reassembly (Fig. 20/ 21)
7.3.4 HMT HSQ Cassette Assembly -
Disassemblyand Reassembly (Fig. 22/ 23)
• With the HLP cassette laid down on it side, remove the three front spacer screws (12) and two reaction block screws (13) followed by the one of HLP cassette side plate (1 or 2).
• Separate the ratchet bush (14). The drive plate assembly is free to be removed from the cassette.
Carefully remove the two compression springs (8) from the drive plate and set to one side.
• Remove the ratchet (4), pawl (5) and pawl springs
(6).
• Disengage the two drive pin retainers (9), and slide out the drive pin (7) from the drive plate (3) .
• On the remaining plate remove the three front spacer screws (12) and two reaction block screws
(13) separate front spacer (11) and reaction block
(10) from the remaining HLP cassette side plate (1 or 2).
• Disassemble the reaction block by removing the two socket head cap screws (17), and remove the wear plate (16) from reaction block spacer (10).
• Clean all components with a mild solvent.
• Inspect all parts for damage. Any damaged components must be replaced.
• Dry all components. Apply a thin coat of molybdenum disulphide grease in the areas shown in Figure 20.
NOTICE Be sure that the ratchet, drive plate, pawl, pawl spring, square drive, access plugs, and compression springs are correctly installed, in the reverse order of disassembly. Failure to install these parts correctly will result in component damage. Refer to figures 19 and 20.
• To separate the square drive reaction arm (4), unscrew the securing reaction arm grub screw (20) and disengage.
• Remove the square drive circlip (8) and slide the reaction arm spline (3) off the square drive
(2). Separate the drive bush (6) and remove the remaining reaction arm circlip (9).
• Remove the square drive (2), drive retainer ring (21), retainer block (5), and push button retainer (16).
• Remove the front spacer pins (22) followed by the front spacer (15).
• The drive plate assembly is free to be removed from the body. Carefully remove the two rod end pin spring (18) from the drive plate and set to one side.
• Disengage the two drive pin retainers (19), and slide out the rod end pin (10) from the drive plate
(11) .
• Remove the splined ratchet (7), pawl ( 14 ) and pawl springs (13).
• If the linkpin (12) requires replacement, unscrew the M4 button head screw (24) and separate link pin and lanyard (23) from the body.
• Clean all components with a mild solvent.
• Inspect all parts for damage. Any damaged components must be replaced.
NOTICE Do not apply molybdenum disulphide 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.
• Dry all components. Apply a thin coat of molybdenum disulphide grease in the areas shown in Figure 22.
• Assemble the HLP cassette assembly to the appropriate drive unit body.
• Connect the wrench to the pump and perform hydraulic pressure testing before placing the wrench into service. Refer to the procedure in Section 7.2.6.
• Without the wrench on a nut or bolt, check operation at a nominal pressure to make sure the piston advances and retracts freely.
• Release the pressure and make sure that the piston fully retracts.
NOTICE Be sure that the ratchet, drive plate, pawl, pawl spring, square drive, access plugs, and compression springs are correctly installed, in the reverse order of disassembly. Ensure that the square drive is inserted through the drive plate. Failure to install these parts correctly will result in component damage.
Refer to figures 21 and 22.
• Assemble the Square Drive Cassette assembly to the appropriate wrench body.
• Connect the wrench to the pump and perform hydraulic pressure testing before placing the wrench into service. Refer to the procedure in Section 7.2.6.
• Without the wrench on a nut or bolt, check operation at a nominal pressure to make sure the piston advances and retracts freely.
• Release the pressure and make sure that the piston fully retracts.
20 L4478_a
1
11
8
❇ Apply Loctite 222 Thread Sealant
✲ Tighten to Torque Value of 1.2 Ft.lbs [1.6 Nm]
7
9
14
2
10
6
12 ❇�
16
17
❇� 3
5
4
13 ❇�
Figure 20: Exploded HMT HLP Cassette
LP3
� LP4
�
✜ molybdenum disulphide grease
LP2
� LP6
�
LP5
�
LP7
�
LP13
�
LP8
�
LP12
�
�
LP10
�
LP1
�
LP9
�
LP11
Lubrication Points - Molybdenum Disulphide Grease:
LP1 Pawl (All Surfaces)
LP2 Bearing Surface
LP3 Bearing Surface
LP4 Drive Bearing Surfaces
LP5 All Surfaces
LP6 Inner Surface
LP7 Bearing Surface
LP8 Bearing Surface
LP9 I Surface
LP10 Inner Surface
LP11 Inner Surface
LP12 Bearing and Inner Surface
LP13 Teeth and Outer Surfaces
Figure 21: HMT HLP Cassette Lubrication Points
L4478_a 21
❇ Apply Loctite 222 Thread Sealant
12
22
23
1
24
❇
16
25
17
2
9
6
18
4
3
21
6
13
14
20
8
Figure 22: Exploded Torque HMT HSQ Cassette
✜ molybdenum disulphide grease
7
15
5
11
10
19
�
LP8
LP4
�
�
LP7
LP2
�
�
LP5
�
LP6
�
LP7
�
LP9
LP2
�
LP3
�
LP1
�
�
LP12
�
LP11
�
LP10
Lubrication Points - Molybdenum Disulphide Grease:
LP1 Pawl (All Surfaces)
LP2 Bearing Surface
LP3 Wrench Body Inner Surfaces
LP4 Square Drive Bearing
LP5 Internal Bearing
LP6 Mating Surface
LP7 Bearing Surface
LP8 Bearing Surface
LP9 Bearing Surface
LP10 All Surfaces
LP11 Internal Surface
LP12 Teeth and Outer Surfaces
Figure 23: HSQ Lubrication Points HMT HSQ Cassette
22 L4478_a
7.3.5 Square Drive Shaft Push Button
Retainer Assembly Disassembly and
Reassembly (Fig. 23)
7.3.6 Hydraulic Pressure Testing
• Connect hydraulic hoses and cycle the wrench at
1,000 psi [69 bar] to check for oil leaks.
NOTICE Disassemble the drive shaft push button retainer assembly only if it is not operating properly or if it is worn or damaged.
1. Remove circlip (25).
• 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.
2. Separate the button mechanism (16) from the retaining block (5).
3. Clean all parts with a mild solvent. Dry all parts after cleaning.
WARNING
Pressurized hydraulic oil can penetrate the skin and could cause serious personal injury. Always repair any oil leaks before using the wrench.
4. Inspect all parts for damage.
5. Reassemble retaining button assembly (16) and bushing (5) and secure with circlip (25).
6. Apply a thin coat of molybdenum disulphide grease in the areas shown in Figure 23.
NOTICE If a fault develops with the retaining button assembly (16), the whole assembly will need to be replaced. It is not recommended that this item be disassembled.
25
16
5
Figure 24: Exploded Push Button Retainer Assembly
L4478_a 23
8. Parts List
8.1 Exploded Views - HMT Drive Unit Exploded View
Note:
Refer to the wrench instruction sheet for detailed maintenance instruction,
✜ Apply molybdenum disulphide grease.
✫
✽
Apply ISO 10 grade oil to O-rings.
Apply Loctite 243 Thread Sealant.
⁂• Tighten to Torque Values:
ο HMT1500 : 6 Ft/lbs [8 Nm]
ο HMT3500 : 14 Ft/lbs [19 Nm]
ο HMT7500 : 30 Ft/lbs [41 Nm]
10
✽
⁂
18
2
15
✫
✫
✫
13
16
8
✴
✫
20
12
12a
1
17
3
�
14
5
✫
✫
11
� �
9
❋
6
4
7 ❋
19
Service Kits:
Items marked
supplied in Back Cap Kit: HMT1500BCK, HMT3500BCK, HMT7500BCK.
Items marked
supplied in Top Retaining Pin Kit: HMT1500TRK, HMT3500TRK, HMT7500TRK.
Items marked
❋
supplied in Bottom Retaining Pin Kit: HMT1500BRK, HMT3500BRK, HMT7500BRK.
Items marked
supplied in Grub Screw Kit: HMT1500GSK, HMT3500GSK, HMT7500GSK.
Items marked
supplied in Seal Kit: HMT1500SK, HMT3500SK, HMT7500SK.
24 L4478_a
8.2 Table of Parts - HMT Drive Unit Exploded View
Item
1
2
3
Description
Drive Unit Body
Back Cap
Piston Rod
Qty
1
1
1
HMT1500 not available
HMT1500-03
Part Numbers
HMT3500 not available
HMT3500-03
HMT7500 not available
HMT7500-03
10
11
8
9
6
7
4
5
Rod End
Bush
Top Retaining Pin
Bottom Retaining Pin
Grub Screw
Ball End Screw
Back Cap Screw
Retaining Ring
8
2
1
1
1
1
1
1
1
HMT1500-04
HMT1500-05
❋
❋
HMT3500-04
HMT3500-05
❋
❋
HMT7500-04
HMT7500-05
❋
❋
12 Swivel Assembly
12a Swivel Seal Kit (not shown)
13
14
Piston Cup Seal
Rod End Seal
1
1
SP300MKA
TSP300MKA
SP300MKA
TSP300MKA
SP300MKA
TSP300MKA
15
16
Back Cap O-Ring
Piston O-Ring
1
1
17
18
19
Lanyard
Screw
Handle
1
1
1
SWH6A
SWH6A
SWH6A
20 O-Ring 1
Indicates items included and available only as part of Back Cap Kit: HMT1500BCK, HMT3500BCK, HMT7500BCK.
Indicates items included and available only as part of Top Retaining Pin Kit: HMT1500TRK, HMT3500TRK, HMT7500TRK.
❋ Indicates items included and available only as part of Bottom Retaining Pin Kit: HMT1500BRK, HMT3500BRK, HMT7500BRK.
Indicates items included and available only as part of Grub Screw Kit: HMT1500GSK, HMT3500GSK, HMT7500GSK.
Indicates items included and available only as part of Seal Kit: HMT1500SK, HMT3500SK, HMT7500SK.
L4478_a 25
8.3 Exploded Views - HMT HLP Cassette Assembly
11
Note:
Refer to the wrench instruction sheet for detailed maintenance instruction,
❇ Apply Loctite 222 Thread Sealant.
✲ Tighten to Torque Value of 1.2 Ft.lbs [1.6 Nm].
1
8
7
9
14
2
10
6
❋
16
17
3
5 ❋
4 ❋
13
Service Kits:
Items marked supplied in Side Plate Kit, see 8.4.1 - 8.4.3 HMT HLP Cassette Service Kits.
Items marked
supplied in Drive Plate Kit, see 8.4.1 - 8.4.3 HMT HLP Cassette Service Kits.
Items marked
❋
supplied in Ratchet Kit see 8.4.1 - 8.4.3 HMT HLP Cassette Service Kits.
Items marked
supplied in Wear Plate Kit, see 8.4.1 - 8.4.3 HMT HLP Cassette Service Kits.
Items marked
supplied in Bushes Kit, see 8.4.1 - 8.4.3 HMT HLP Cassette Service Kits.
Items marked
See 8.4.4 HMT HLP Cassette Reaction Block Spacer/ Front Spacer part numbers.
Items marked
supplied in Screw Kit: HLP1500SCK, HLP3500SCK, HLP7500SCK.
12
26 L4478_a
8.4 Table of Parts - HMT HLP Cassette Assembly
Item Description Qty
Part Numbers
HMT1500 Cassettes HMT3500 Cassettes HMT7500 Cassettes
1
2
3
Left Side Plate
Right Side Plate
Drive Plate
1
1
1
6
7
4
5
Hex Ratchet
Drive Pawl
Drive Pawl Spring
Drive Pin
2
1
1
1
❋
❋
❋
❋
❋
❋
❋
❋
❋
10
11
8
9
Drive Pin Spring
Drive Pin Retainer
Reaction Block Space
Front Space
1
1
2
2
12
13
14
15
Front Space Screw
Reaction Block Screw
Ratchet Bush
Crush Hazard Sticker
(not shown)
Wear Plate
6
4
2
2
★
★
★
16 1
17 Screw 2
Indicates items included and available only as part of Side Plate Kit, see 8.4.1/ 8.4.2/ 8.4.3 HMT HLP Cassette
Service Kits.
❋
Indicates items included and available only as part of Drive Plate Kit, see 8.4.1/ 8.4.2/ 8.4.3 HMT HLP Cassette
Service Kits.
Indicates items included and available only as part of Ratchet Kit see 8.4.1/ 8.4.2/ 8.4.3 HMT HLP Cassette
Service Kits.
★
Indicates items included and available only as part of Wear Plate Kit, see 8.4.1/ 8.4.2/ 8.4.3 HMT HLP Cassette
Service Kits.
Indicates items included and available as part of Bushes Kit, see 8.4.1/ 8.4.2/ 8.4.3 HMT HLP Cassette Service
Kits.
See 8.4.4 HMT HLP Cassette Reaction Block Spacer/ Front Spacer part numbers.
Indicates items included and available only as part of Screw Kit: HLP1500SCK, HLP3500SCK, HLP7500SCK.
L4478_a 27
HLP1101
HLP1102
HLP1103
HLP1104
HLP1113
HLP1114
HLP1115
HLP1200
HLP1201
HLP1202
HLP1203
HLP1204
HLP1105
HLP1106
HLP1107
HLP1108
HLP1109
HLP1110
HLP1111
HLP1112
HLP1205
HLP1206
HLP1207
8.4.1 HMT1500 HLP Cassette Service Kits
Cassette Model
Side Plate Kit
(Section 8.3/8.4, item 1,2,14,15)
Drive Plate Kit
(Section 8.3/8.4, item 3,7,8,9)
HLP1500175103 HLP1103DPK
HLP1500175103 HLP1103DPK
HLP1500175103 HLP1103DPK
HLP1500175105 HLP1105DPK
HLP1500175105 HLP1105DPK
HLP1500175107 HLP1107DPK
HLP1500175107 HLP1107DPK
HLP1500175111 HLP1111DPK
HLP1500175111 HLP1111DPK
HLP1500175111 HLP1111DPK
HLP1500175111 HLP1111DPK
HLP1500175113 HLP1113DPK
HLP1500175113 HLP1113DPK
HLP1500175201 HLP1201DPK
HLP1500175201 HLP1201DPK
HLP1500175201 HLP1201DPK
HLP1500175201 HLP1201DPK
HLP1500175205 HLP1205DPK
HLP1500175205 HLP1205DPK
HLP1500175205 HLP1205DPK
HLP1500175205 HLP1205DPK
HLP1500175207 HLP1207DPK
HLP1500175207 HLP1207DPK
Part Numbers
Ratchet Kit
(Section 8.3/8.4, item 4,5,6)
HLP1101RK
HLP1102RK
HLP1103RK
HLP1104RK
HLP1105RK
HLP1106RK
HLP1107RK
HLP1108RK
HLP1109RK
HLP1110RK
HLP1111RK
HLP1112RK
HLP1113RK
HLP1114RK
HLP1115RK
HLP1200RK
HLP1201RK
HLP1202RK
HLP1203RK
HLP1204RK
HLP1205RK
HLP1206RK
HLP1207RK
Wear Plate Kit
(Section 8.3/8.4, item 17, 18)
Bushes Kit
(Section 8.3/8.4, item 14)
HLP1105WPK HLP1500-14-01
HLP1105WPK HLP1500-14-01
HLP1105WPK HLP1500-14-01
HLP1105WPK HLP1500-14-02
HLP1105WPK HLP1500-14-02
HLP1107WPK HLP1500-14-03
HLP1107WPK HLP1500-14-03
HLP1105WPK HLP1500-14-04
HLP1105WPK HLP1500-14-04
HLP1105WPK HLP1500-14-04
HLP1105WPK HLP1500-14-04
HLP1105WPK HLP1500-14-05
HLP1105WPK HLP1500-14-05
HLP1207WPK HLP1500-14-06
HLP1207WPK HLP1500-14-06
HLP1207WPK HLP1500-14-06
HLP1207WPK HLP1500-14-06
HLP1207WPK HLP1500-14-07
HLP1207WPK HLP1500-14-07
HLP1207WPK HLP1500-14-07
HLP1207WPK HLP1500-14-07
HLP1207WPK HLP1500-14-08
HLP1207WPK HLP1500-14-08
28 L4478_a
HLP3106
HLP3107
HLP3200
HLP3201
HLP3202
HLP3203
HLP3204
HLP3205
HLP3206
HLP3207
HLP3108
HLP3109
HLP3110
HLP3111
HLP3112
HLP3113
HLP3114
HLP3115
HLP3208
HLP3209
HLP3210
HLP3211
HLP3212
HLP3213
HLP3214
HLP3215
HLP3300
HLP3301
HLP3302
8.4.2 HMT3500 HLP Cassette Service Kits
Cassette Model
Side Plate Kit
(Section 8.3/8.4, item 1,2,14,15)
Drive Plate Kit
(Section 8.3/8.4, item 3,7,8,9)
HLP3500175107 HLP3107DPK
HLP3500175107 HLP3107DPK
Part Numbers
Ratchet Kit
(Section 8.3/8.4, item 4,5,6)
HLP3106RK
Wear Plate Kit
(Section 8.3/8.4, item 17, 18)
Bushes Kit
(Section 8.3/8.4, item 14)
HLP3204WPK HLP3500-14-01
HLP3107RK HLP3204WPK HLP3500-14-01
HLP3500175111 HLP3111DPK
HLP3500175111 HLP3111DPK
HLP3500175111 HLP3111DPK
HLP3500175111 HLP3111DPK
HLP3500175113 HLP3113DPK
HLP3500175113 HLP3113DPK
HLP3500175201 HLP3201DPK
HLP3500175201 HLP3201DPK
HLP3500175201 HLP3201DPK
HLP3500175201 HLP3201DPK
HLP3500175204 HLP3204DPK
HLP3500175204 HLP3204DPK
HLP3500175204 HLP3204DPK
HLP3500175207 HLP3207DPK
HLP3500175207 HLP3207DPK
HLP3500175207 HLP3207DPK
HLP3500175209 HLP3209DPK
HLP3500175209 HLP3209DPK
HLP3500175214 HLP3214DPK
HLP3500175214 HLP3214DPK
HLP3500175214 HLP3214DPK
HLP3500175214 HLP3214DPK
HLP3500175214 HLP3214DPK
HLP3500175215 HLP3215DPK
HLP3500175302 HLP3302DPK
HLP3500175302 HLP3302DPK
HLP3500175302 HLP3302DPK
HLP3108RK
HLP3109RK
HLP3110RK
HLP3111RK
HLP3112RK
HLP3113RK
HLP3114RK
HLP3115RK
HLP3200RK
HLP3201RK
HLP3202RK
HLP3203RK
HLP3204RK
HLP3205RK
HLP3206RK
HLP3207RK
HLP3208RK
HLP3209RK
HLP3210RK
HLP3211RK
HLP3212RK
HLP3213RK
HLP3214RK
HLP3215RK
HLP3300RK
HLP3301RK
HLP3302RK
HLP3204WPK HLP3500-14-02
HLP3204WPK HLP3500-14-02
HLP3204WPK HLP3500-14-02
HLP3204WPK HLP3500-14-02
HLP3204WPK HLP3500-14-03
HLP3204WPK HLP3500-14-03
HLP3204WPK HLP3500-14-04
HLP3204WPK HLP3500-14-04
HLP3204WPK HLP3500-14-04
HLP3204WPK HLP3500-14-04
HLP3204WPK HLP3500-14-05
HLP3204WPK HLP3500-14-05
HLP3204WPK HLP3500-14-05
HLP3214WPK HLP3500-14-06
HLP3214WPK HLP3500-14-06
HLP3214WPK HLP3500-14-06
HLP3214WPK
HLP3214WPK
HLP3214WPK
HLP3214WPK
HLP3214WPK
HLP3214WPK
HLP3214WPK
HLP3204WPK
HLP3204WPK
HLP3204WPK
HLP3204WPK
HLP3500-14-07
HLP3500-14-07
HLP3500-14-08
HLP3500-14-08
HLP3500-14-08
HLP3500-14-08
HLP3500-14-08
HLP3500-14-09
HLP3500-14-10
HLP3500-14-10
HLP3500-14-10
L4478_a 29
HLP7203
HLP7204
HLP7205
HLP7206
HLP7207
HLP7208
HLP7209
HLP7210
HLP7211
HLP7212
HLP7213
HLP7214
HLP7215
HLP7300
HLP7301
HLP7302
HLP7304
HLP7085M
HLP7090M
HLP7306
HLP7308
HLP7309
HLP7312
HLP7314
8.4.3 HMT7500 HLP Cassette Service Kits
Cassette Model
Side Plate Kit
(Section 8.3/8.4, item 1,2,14,15)
Drive Plate Kit
(Section 8.3/8.4, item 3,7,8,9)
HLP7500175205 HLP7205DPK
Part Numbers
Ratchet Kit
(Section 8.3/8.4, item 4,5,6)
HLP7203RK
Wear Plate Kit
(Section 8.3/8.4, item 17, 18)
Bushes Kit
(Section 8.3/8.4, item 14)
HLP7205WPK HLP7500-14-02
HLP7500175205 HLP7205DPK
HLP7500175205 HLP7205DPK
HLP7500175208 HLP7208DPK
HLP7500175208 HLP7208DPK
HLP7204RK
HLP7205RK
HLP7206RK
HLP7207RK
HLP7205WPK
HLP7205WPK
HLP7215WPK
HLP7215WPK
HLP7500-14-02
HLP7500-14-02
HLP7500-14-03
HLP7500-14-03
HLP7500175208 HLP7208DPK
HLP7500175209 HLP7209DPK
HLP7500175214 HLP7214DPK
HLP7500175214 HLP7214DPK
HLP7500175214 HLP7214DPK
HLP7500175214 HLP7214DPK
HLP7500175214 HLP7214DPK
HLP7500175215 HLP7215DPK
HLP7208RK
HLP7209RK
HLP7210RK
HLP7211RK
HLP7212RK
HLP7213RK
HLP7214RK
HLP7215RK
HLP7215WPK HLP7500-14-03
HLP7215WPK HLP7500-14-04
HLP7215WPK HLP7500-14-05
HLP7215WPK HLP7500-14-05
HLP7215WPK HLP7500-14-05
HLP7215WPK HLP7500-14-05
HLP7215WPK HLP7500-14-05
HLP7215WPK HLP7500-14-06
HLP7500175302 HLP7302DPK
HLP7500175302 HLP7302DPK
HLP7500175302 HLP7302DPK
HLP7500175306 HLP7306DPK
HLP7300RK
HLP7301RK
HLP7302RK
HLP7304RK
HLP7205WPK HLP7500-14-07
HLP7205WPK HLP7500-14-07
HLP7205WPK HLP7500-14-07
HLP7205WPK HLP7500-14-08
HLP7500175306 HLP7306DPK HLP7085MRK HLP7205WPK HLP7500-14-08
HLP7500175090 HLP7090MPK HLP7090MRK HLP7308WPK HLP7500-14-09
HLP7500175306 HLP7306DPK
HLP7500175090 HLP7090MPK
HLP7306RK
HLP7308RK
HLP7205WPK
HLP7308WPK
HLP7500-14-08
HLP7500-14-09
HLP7500175312 HLP7312DPK
HLP7500175312 HLP7312DPK
HLP7500175314 HLP7314DPK
HLP7309RK
HLP7312RK
HLP7314RK
HLP7314WPK HLP7500-14-10
HLP7314WPK HLP7500-14-10
HLP7314WPK HLP7500-14-11
30 L4478_a
HLP1200
HLP1201
HLP1202
HLP1203
HLP1204
HLP1205
HLP1206
HLP1207
HLP3106
HLP3107
HLP3108
HLP3109
HLP3110
HLP3111
HLP3112
HLP3113
HLP1101
HLP1102
HLP1103
HLP1104
HLP1105
HLP1106
HLP1107
HLP1108
HLP1109
HLP1110
HLP1111
HLP1112
HLP1113
HLP1114
HLP1115
HLP3114
HLP3115
HLP3200
HLP3201
HLP3202
HLP3203
HLP3204
8.4.4 HMT HLP Cassette Reaction Block Spacer/ Front Spacer Part Numbers
Cassette Model
Part Numbers
Reaction Block
Space
(Section 8.3/8.4, item 10)
Front Spacer
(Section 8.3/8.4, item 11)
HLP1500-09-01 HLP1500-10-01
HLP1500-09-01 HLP1500-10-01
HLP1500-09-01 HLP1500-10-01
HLP1500-09-02 HLP1500-10-02
HLP1500-09-02 HLP1500-10-02
HLP1500-09-03 HLP1500-10-03
HLP1500-09-03 HLP1500-10-03
HLP1500-09-04 HLP1500-10-04
HLP1500-09-04 HLP1500-10-04
HLP1500-09-04 HLP1500-10-04
HLP1500-09-04 HLP1500-10-04
HLP1500-09-05 HLP1500-10-05
HLP1500-09-05 HLP1500-10-05
HLP1500-09-06 HLP1500-10-06
HLP1500-09-06 HLP1500-10-06
HLP1500-09-06 HLP1500-10-06
HLP1500-09-06 HLP1500-10-06
HLP1500-09-07 HLP1500-10-07
HLP1500-09-07 HLP1500-10-07
HLP1500-09-07 HLP1500-10-07
HLP1500-09-07 HLP1500-10-07
HLP1500-09-08 HLP1500-10-08
HLP1500-09-08 HLP1500-10-08
HLP3500-09-01 HLP3500-10-01
HLP3500-09-01 HLP3500-10-01
HLP3500-09-02 HLP3500-10-02
HLP3500-09-02 HLP3500-10-02
HLP3500-09-02 HLP3500-10-02
HLP3500-09-02 HLP3500-10-02
HLP3500-09-03 HLP3500-10-03
HLP3500-09-03 HLP3500-10-03
HLP3500-09-04 HLP3500-10-04
HLP3500-09-04 HLP3500-10-04
HLP3500-09-04 HLP3500-10-04
HLP3500-09-04 HLP3500-10-04
HLP3500-09-05 HLP3500-10-05
HLP3500-09-05 HLP3500-10-05
HLP3500-09-05 HLP3500-10-05
Cassette Model
HLP7204
HLP7205
HLP7206
HLP7207
HLP7208
HLP7209
HLP7210
HLP7211
HLP7212
HLP7213
HLP7214
HLP7215
HLP7300
HLP7301
HLP7302
HLP7304
HLP3205
HLP3206
HLP3207
HLP3208
HLP3209
HLP3210
HLP3211
HLP3212
HLP3213
HLP3214
HLP3215
HLP3300
HLP3301
HLP3302
HLP7203
HLP7085M
HLP7090M
HLP7306
HLP7308
HLP7309
HLP7312
HLP7314
Part Numbers
Reaction Block
Space
(Section 8.3/8.4, item 10)
Front Spacer
(Section 8.3/8.4, item 11)
HLP3500-09-06 HLP3500-10-06
HLP3500-09-06 HLP3500-10-06
HLP3500-09-06 HLP3500-10-06
HLP3500-09-07 HLP3500-10-07
HLP3500-09-07 HLP3500-10-07
HLP3500-09-08 HLP3500-10-08
HLP3500-09-08 HLP3500-10-08
HLP3500-09-08 HLP3500-10-08
HLP3500-09-08 HLP3500-10-08
HLP3500-09-08 HLP3500-10-08
HLP3500-09-09 HLP3500-10-09
HLP3500-09-10 HLP3500-10-10
HLP3500-09-10 HLP3500-10-10
HLP3500-09-10 HLP3500-10-10
HLP7500-09-02 HLP7500-10-02
HLP7500-09-02 HLP7500-10-02
HLP7500-09-02 HLP7500-10-02
HLP7500-09-03 HLP7500-10-03
HLP7500-09-03 HLP7500-10-03
HLP7500-09-03 HLP7500-10-03
HLP7500-09-04 HLP7500-10-04
HLP7500-09-05 HLP7500-10-05
HLP7500-09-05 HLP7500-10-05
HLP7500-09-05 HLP7500-10-05
HLP7500-09-05 HLP7500-10-05
HLP7500-09-05 HLP7500-10-05
HLP7500-09-06 HLP7500-10-06
HLP7500-09-07 HLP7500-10-07
HLP7500-09-07 HLP7500-10-07
HLP7500-09-07 HLP7500-10-07
HLP7500-09-08 HLP7500-10-08
HLP7500-09-08 HLP7500-10-08
HLP7500-09-09 HLP7500-10-09
HLP7500-09-08 HLP7500-10-08
HLP7500-09-09 HLP7500-10-09
HLP7500-09-10 HLP7500-10-10
HLP7500-09-10 HLP7500-10-10
HLP7500-09-11 HLP7500-10-11
L4478_a 31
8.5 Exploded Views - HMT Extended Reaction Arm
1
2
8.6 Table of Parts - HMT Extended Reaction Arm Assembly
Item Description Qty
1 Extended Reaction Arm ★
1
2 Reaction Arm Pin 1
HMT1500
HTE15
RAP15
Part Numbers
HMT1500
HTE35
RAP35
★ Dispatched as assembly including appropriate Reaction Arm Pin to suit.
HMT1500
HTE75
RAP75
32 L4478_a
8.7 Exploded Views - HMT Reaction Paddle
1
2
8.8 Table of Parts - HMT Reaction Paddle Assembly
Item
1
2
Description
Reaction Paddle ★
Reaction Paddle Pin
Qty
1
1
HMT1500
HRP15
RPP15
Part Numbers
HMT1500
HRP35
RPP35
★ Dispatched as assembly including appropriate Reaction Paddle Pin to suit.
HMT1500
HRP75
RPP75
L4478_a 33
8.9 Exploded Views - HMT HSQ Square Drive Cassette Assembly
Note:
Refer to the wrench instruction sheet for detailed maintenance instruction,
❇ Apply Loctite 222 Thread Sealant
1
24
❇
22
12
23
25
16 17
5
2
15
9
6 18
4
3
21
6
13 ❋
14 ❋
20
7
❋
8
Service Kits:
Items marked
supplied in Reaction Spline Kit: HSQ1500RSPK, HSQ3500RSPK, HSQ7500RSPK.
Items marked
supplied in Drive Plate Kit: HSQ1500DPK, HSQ3500DPK, HSQ7500DPK.
Items marked
❋
supplied in Ratchet Kit: HSQ1500RK, HSQ3500RK, HSQ7500RK.
Items marked
dispatched alongside Reaction Arm: HSQ1500-04, HSQ3500-04, HSQ7500-04.
Items marked
dispatched alongside Square Drive: HSQ1500-02, HSQ3500-02, HSQ7500-02.
Items marked supplied in Push Button Retainer Assembly: PBR02A.
Items marked supplied in Push Button Retainer Assembly: PBR03A.
11
10
19
34 L4478_a
8.10 Table of Parts - HMT HSQ Square Drive Cassette Assembly
Item Description Qty
HSQ1500
Part Numbers
HSQ3500 HSQ7500
1
HSQ Square Drive Cassette
Body
Square Drive
1
2
3
4
5
Reaction Arm Spline
Reaction Arm
6
7
Retainer Block
Drive Bush
8
9
Splined Ratchet
Square Drive Circlip
10
11
12
13
14
Reaction Arm Circlip
Rod End Pin
Drive Plate
Link Pin Assembly
Pawl Spring
Pawl 1
15
16
Front Spacer
Push Button Retainer
Assembly
1
1
17 Pin Retainer Grub Screw 1
1
1
1
1
1
2
2
1
1
1
1
1
18
19
Rod End Pin Spring
Drive Pin Retainer
20 Reaction Arm Grub Screw 1
21 Drive Retainer Ring 1
2
2
22 Front Spacer Pin 2
Not available
HSQ1500-02
HSQ1500-03
HSQ1500-04
❋
HSQ1500-12
❋
❋
Not available
Not available
Not available
Not available
HSQ3500-02
HSQ3500-03
HSQ3500-04
❋
HSQ3500-12
❋
❋
Not available
Not available
Not available
Not available
HSQ7500-02
HSQ7500-03
HSQ7500-04
❋
HSQ7500-12
❋
❋
Not available
Not available
Not available
23 Link Pin Assembly Lanyard 1
24 M4 Button Head 1
HSQ1500-12
HSQ1500-12
HSQ3500-12
HSQ3500-12
HSQ7500-12
HSQ7500-12
25 Drive Retainer Clip 1
Indicates items included and available only as part of Reaction Spline Kit: HSQ1500RSPK, HSQ3500RSPK,
HSQ7500RSPK.
Indicates items included and available only as part of Drive Plate Kit: HSQ1500DPK, HSQ3500DPK, HSQ7500DPK.
❋ Indicates items included and available only as part of Ratchet Kit: HSQ1500RK, HSQ3500RK, HSQ7500RK.
Dispatched alongside Reaction Arm: HSQ1500-04, HSQ3500-04, HSQ7500-04.
Dispatched alongside Square Drive: HSQ1500-02, HSQ3500-02, HSQ7500-02.
Indicates items included and available only as part of Push Button Retainer Assembly: PBR02A.
Indicates items included and available only as part of Push Button Retainer Assembly: PBR03A.
L4478_a 35
8.11 Exploded Views - Swivel Assembly
Note:
Refer to the wrench instruction sheet for detailed maintenance instruction,
✤ Apply silicone grease to O-rings.
⁑ Tighten to Torque Value of 5.9 Ft.lbs [8 Nm].
✽ Apply Loctite 243 Thread Sealant (inside bolt holes).
✴ Apply Loctite 577 Thread Sealant (thread of B1 and
B2).
10
7
�
�
8
1
11
� 2 9
3
✤
�
✽
6
Service Kits:
Items marked supplied in Swivel Assembly.
Items marked supplied in Swivel Seal Kits.
✤
5
4
36 L4478_a
8.12 Table of Parts - Swivel Assembly
Item
1
2
3
Description
Circlip
Swivel Manifold Block
O-Ring
Qty
1
2
3
Part Numbers
6
7
4
5
Socket Head Capscrews
Swivel Manifold Post
O-Ring
Adaptor [10,000 psi]
4
1
2
SP300101
8
9
Male Coupling [10,000 psi]
Female Coupling [10,000 psi]
10 Dust Cap for male coupler 1
11 Dust Cap for female coupler 1
Indicates items included and available only as part of Swivel Assembly: SP300MKA.
Indicates items included and available only as part of Swivel Seal Kit: TSP300MKA.
L4478_a 37
9. Troubleshooting
Fault
Ratchet will not turn
(HLP Cassette Assembly only)
Wrench pressure will not build
Piston will not advance
Piston will not retract
Pressure reading erratic
Pump will not build up pressure
Possible Cause
Grease or dirt build up in the teeth of the ratchet and segment pawl
Worn or broken teeth on ratchet and/or segment pawl
Piston seal and/or end plug seal leaking
Retaining screws sheared
Coupler is defective
Couplers are not securely attached to the tool and /or pump
Coupler is defective
Defective remote control unit
Dirt in the direction-control valve of the pump unit
Hose connections reversed
Retract hose not connected
Retract pin and/or spring broken
Defective gauge
Defective relief valve
Air supply too low or air hose too small
Electric power source is too low
Defective gauge
Low oil level
Clogged filter
Corrective Action
Disassemble the ratchet and clean the grease or dirt out of the teeth.
Replace any worn or damaged parts.
Replace any defective o-rings.
Replace any broken screws.
Replace any defective couplers.
Check the coupler connections and make certain that they are connected.
Replace any defective couplers.
Replace the button and/or control pendant.
Disassemble the pump and clean the direction-control valve.
Check the advance on the pump is connected to the advance on the wrench and the retract on the pump is connected to the retract on the wrench.
Connect the retract hose securely.
Replace the broken pin and/or spring.
Replace the gauge.
Inspect, adjust or replace the relief valve.
Make certain the air supply and hose size comply with the pump manual recommendations.
Make certain the amperage, voltage and any extension cord size comply with the pump manual requirements.
Replace the gauge.
Check and fill the pump reservoir.
Inspect, clean and/or replace the pump filter.
Refer to the Pump Instruction Sheet for troubleshooting required for the pump unit.
38 L4478_a
NOTES
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41
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