REL-46 Manual 01-10.p65

OPERA T

ORS’

GUIDE

REL-46

15 TON SINGLE ACTING

REMOTE HYDRAULIC

CRIMPING HEAD

Compatible with RELIABLE

R15 and “P” Style dies.

All information found in this guide

must be read and understood before

use or testing of this tool.

Failure to read and understand these warnings and safe handling instructions could result in severe personal injury and or death.

RELIABLE EQUIPMENT & SERVICE CO., INC.

92 Steamwhistle Drive • Ivyland, PA 18974 • USA

Phone: 215-357-3500 • Fax: 215-357-9193

MODEL: ___________________________________

MAX. PRESSURE: __________________________

SERIAL NO.: _______________________________

YEAR: ____________________________________

Sizes, weights and tool specifications listed in this manual are subject to change without notice.

Please consult factory for information and updates.

DISTRIB

UTED BY

DISTRIB

UTED BY

REGISTRATION

UPON RECEIPT OF THIS TOOL, COMPLETE THE REGISTRATION BELOW.

COMPANY _____________________________________________________

ADDRESS ______________________________________________________

_______________________________________________________________

PHONE ____________________ FAX _______________________________

SERIAL NUMBER _______________________________________________

DATE OF PURCHASE ___________________________________________

DEALER NAME _________________________________________________

CAUTION

The information in this manual is intended to guide the user in the use and application of this tool. It is not intended as a substitute for proper training and experience in safe work practices for this type of equipment.

Consult your supervisor or safety personnel if you have any questions regarding the safe operation of this tool.

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TABLE OF CONTENTS

DISTRIBUTOR INFORMATION .......................................................... 2

REGISTRATION .................................................................................... 2

TABLE OF CONTENTS ....................................................................... 3

TOOL SPECIFICATIONS

REL-46 - MANUAL HYDRAULIC

15 TON COMPRESSION TOOL ........................................... 4

SAFETY INFORMATION AND WARNINGS ................................... 5-9

OPERATING INSTRUCTIONS .......................................................... 1 0

DAILY MAINTENANCE ...................................................................... 11

GENERAL MAINTENANCE ............................................................... 11

LABEL SET ......................................................................................... 1 2

PARTS LIST ........................................................................................ 1 2

PARTS DRAWING ............................................................................... 1 3

MAINTENANCE RECORDS .............................................................. 1 4

CONTACT INFORMATION ................................................................ 1 4

If you have any questions regarding the information found in this manual please contact RELIABLE EQUIPMENT at 800-966-3530 or FAX 215-357-9193.

THIS SYMBOL INDICATES ITEMS OF EXTREME IMPORTANCE.

Safety of user and others may be in jeopardy if these instructions are not read and understood.

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REL-46

Compatible with RELIABLE R15 and “P” Style dies.

15 TON SINGLE ACTING

HYDRAULIC CRIMPING TOOL

SPECIFICATIONS

The REL-46 Single Acting Hydraulic 15 ton

Crimping Head. Easy, one-hand operation, and 360

O

rotating head allows easy head orientation for precision control of crimping to improve safety and reliability.

System

Jaw Capacity

Crimping Force

Oper. Pressure

Single-Acting

2 inch

24,300 lb.

10,000 psi (690 bar)

Accepts R15 and “P” style dies to crimp connector sizes up to 1,250 MCM-CU.

Couplers 3/8 inch Female

Dies Accepted Y-46 or Equal

With an optional PU adaptor this tool will accept Reliable R12 or “U” style dies as well as some dies from Alcoa, Burndy, Thomas

& Betts, and Blackburn.

W/ PU Adaptor

Head Rotation

Y-35 or Equal

360

O

Weight: 10 lbs.

Length: 10.5 inches

Width: 6 inches

4

92 Steamwhistle Drive • Ivyland, PA 18974

Phone: 800-966-3530 • Fax: 215-357-9193

Visit us on the web at www.Reliable-Equip.com

BEFORE USING THIS TOOL, READ THE WARNINGS and the recommended practices described in this manual.

Failure by the operator to read and fully understand these warnings will leave this person unqualified to use and operate this tool. Property damage, severe personal injury, and/or death could result by not following these warnings.

WARNING

These warnings will appear in appropriate locations when they are pertinent to the particular subject being shown. Read each one carefully and follow them strictly.

Eye

Protection

WARNING

Always wear eye protection to avoid injury from flying debris or hydraulic oil leaks. Failure to do so can result in serious personal injury.

Skin

Irritation

WARNING

Hydraulic oil may cause irritation.

Use care to prevent contact with skin.

In case of accidental contact, wash affected area immediately

Hard Hat

WARNING

Always wear a hard hat to avoid injury from falling debris. Failure to do so can result in serious personal injury.

Foot

Protection

WARNING

Always wear foot protection.

Failure to do so can result in serious personal injury.

Hearing

Protection

WARNING

Always wear hearing protection, to avoid hearing loss due to long term exposure to high noise levels.

Protective

Gloves

WARNING

Always wear protective gloves

Failure to do so can result in serious personal injury.

5

WARNING

SAFE OPERATION & CARE

USE THIS TOOL FOR ITS INTENDED PURPOSE ONLY

Any other use can result in personal injury or property damage.

INSPECT TOOL BEFORE USE. Replace any worn, damaged or missing parts. A damaged or improperly assembled tool may malfunction, injuring operator and/or nearby personnel.

INSPECT HYDRAULIC HOSES AND COUPLINGS before each use. Repair or replace if any cracking, leakage, wear or damage is found. Worn or damaged hoses may fail resulting in personal injury or property damage.

CLEAR WORK AREA of all bystanders and unnecessary personnel before operating this tool.

KEEP ALL PARTS OF THE BODY AWAY FROM MOVING PARTS.

Failure to observe this warning could result in serious injury.

WARNING

HYDRAULIC POWER SUPPLY

DO NOT attempt to make any changes to any of the component parts or accessories when connected to the power source.

DO NOT adjust, inspect, or clean tool while the tool is connected to the power source. The tool could accidentally start up and cause serious injury.

DO NOT lock the tool in the On Position. In an emergency, serious damage or injury could occur during the time required to stop the tool.

WARNING

OIL INJECTION INJURY

Hydraulic oil or fluid under the skin is a serious injury. Oil under pressure can penetrate the skin and may cause dismemberment or loss of life. Seek medical assistance immediately if such an injury should occur.

Always wear safety gloves, eye protection and all required safety equipment when operating or handling this tool.

DO NOT use fingers or hands to attempt to locate a leak.

DO NOT handle hoses or couplers while system is pressurized.

NEVER open or service the system before depressurizing.

6

WARNING

HOSES AND FITTINGS

There exists the potential for shock in using anything other than certified nonconductive hoses and hydraulic oil with dielectric properties, when using system components near energized electrical lines. Failure to recognize these conditions could cause electrocution.

Hoses and fittings used with this tool must comply with S.A.E. J1273 which covers recommended practice for selection, installation, and maintenance of hose and hose assemblies. The correct hoses and fittings are available from your supplier.

WARNING: Failure to comply with these warnings could result in severe bodily injury.

WARNING

UNIT/HOSE CONNECTIONS

ALWAYS DISCONNECT pump/power source and move toggle switch to OFF before connecting or disconnecting any components.

ALWAYS DEPRESSURIZE hydraulic system, before slowly disconnecting this unit or any of the systems components.

ALWAYS TIGHTEN couplings completely. Loose or improperly tightened couplings will not allow fluid to pass through the hose creating a blockage in the supply or return line.

ALWAYS INSPECT HOSES AND CONNECTORS b e f o r e connection to tool. Replace or repair if any leakage is evident.

Leakage is a sign of deterioration in component parts. Worn or leaking parts must be repaired or replaced, or tool damage or severe injury could result.

WARNING

Operation/Safety methods may vary in accordance

with the working guidelines established by each utility or contractor.

For your own safety, ensure that you fully comply with all safe operation guidelines required by your employer.

WARNING

ELECTRICAL SHOCK HAZARD

Always wear and use the necessary clothing, equipment and safety practices to protect against electrical shock. Failure to follow these rules can result in serious personal injury or death.

7

WARNING

SERIOUS BURN HAZARD

HOT SURFACES MAY CAUSE SERIOUS BURNS.

The hydraulic cylinder may be hot during and after operation.

CA UTION:

Never disconnect tool, hoses, or fittings while the hydraulic power source is running or if the hydraulic fluid is hot.

Failure to observe this warning could result in serious injury.

WARNING

CRIMP DANGER

This hydraulic crimping tool can crush and/or disable.

KEEP ALL PARTS OF THE BODY AWAY FROM MOVING PARTS.

DO NOT lock the tool in the On Position. In an emergency,

.

serious damage or injury could occur during the time required to stop the tool.

Failure to observe this warning could result in serious injury

WARNING

TOOL HAZARD

DO NOT OPERATE TOOL WITHOUT DIES.

DO NOT EXCEED THE MAXIMUM HYDRAULIC FLOW, RELIEF

PRESSURE, OR BACK PRESSURE.

Failure to observe warnings could result in tool damage or injury.

An incomplete crimp may pose a fire hazard.

Always use the appropriate connector, die set, and compression tool, as required by the intended application.

Compression tool should be tested on a regular schedule to ensure acurate compression.

Failure to observe this warning could result in serious injury.

IF YOU HAVE ANY QUESTIONS REGARDING THE SAFE USE

AND/OR OPERATION OF THIS TOOL, CONSULT YOUR AREA SUPERVISOR,

OR CONTACT RELIABLE EQUIPMENT AT 800-966-3530

8

THIS TOOL CAN CAUSE SEVERE INJURY

JAW CLOSES QUICKLY & WITH EXTREME FORCE

KEEP ALL BODY PARTS OUTSIDE DANGER ZONE

USE ALL APPROPRIATE AND APPLICABLE PERSONAL SAFETY EQUIPMENT

as required by the operating company.

INSPECT TOOL BEFORE USE. Replace any worn, damaged or missing parts.

A damaged or improperly assembled tool may injure operator and/or nearby personnel.

KEEP ALL PARTS OF THE BODY AWAY from moving parts of the tool.

ALL BODY PARTS SHOULD BE OUTSIDE DANGER ZONE PRIOR TO COMPRESSION.

MAKE SURE there is no person in close proximity to you or the tool who could be injured by any operation being performed, tool malfunction or flying debris.

DO NOT OVEREXTEND your position by overreaching or unbalancing the footing necessary to maintain physical control of your body and the tool.

ALWAYS MAINTAIN a firm grip on the tool to avoid loss of control during an operation, causing property damage, serious injury or death.

USE THIS TOOL FOR THE MANUFACTURERS’ INTENDED PURPOSE ONLY.

OBSERVE CLOSELY ALL OF THE SAFETY RULES FOR A PARTICULAR JOB CLASS

Operation/Safety methods may vary in accordance with the working guidelines established by each utility or contractor. Ensure that you fully comply with all safe operation guidelines required by your employer.

FAILURE TO HEED SAFETY WARNINGS MAY RESULT IN

PROPERTY DAMAGE, SERIOUS INJURY OR DEATH

WARNING

Inspection & Testing requirements may vary in accordance with the working guidelines established by each utility or contractor.

For your own safety, ensure that you fully comply with all safe operation guidelines required by your employer.

IF YOU HAVE ANY QUESTIONS REGARDING THE PROPER USE

AND/OR OPERATION OF THIS TOOL, CONSULT YOUR AREA SUPERVISOR,

OR CONTACT RELIABLE EQUIPMENT AT 800-966-3530

9

OPERA

TION

Read entire manual prior to using this tool. (Refer to all safety recommendations and warnings)

Observe all safety precautions and procedures required by the operating company.

(Also refer to SAFETY information found on pages 5 through 9)

Before crimping, ensure that crimp is within the capacity listed for the tool.

Refer to connector manufacturer’s instructions for cable preparation and crimping procedure.

Ensure that you are using the proper die, as recommended by the connector manufacturer.

WARNING: DO NOT OPERATE TOOL WITHOUT COMPRESSION DIES

1.

Ensure that proper 10,000 psi power source is turned OFF and valve is in OFF position.

2.

Connect to a 10,000 PSI power source with audible “Pop Off” type relief valve.

(Recommended) Refer to page 7 UNIT/HOSE CONNECTION

3.

Ensure that the ram is fully retracted.

4

.

Insert proper die into die seat.

DIE INSTALLATION

This tool uses R15 and “P” type 15 ton dies.

With an optional PU Adaptor this tool will accept standard R12 and “U” style 12 ton dies.

Press die retainer button and slide “P” type die onto die retainer.

Ensure that die is secure.

Press button on adapter and slide “U” die under retaining lip.

Ensure that die is secure.

Press die retainer button and slide PU

Adapter onto die retainer.

Ensure that die is secure.

Ensure that you are using the proper die, as recommended by the connector manufacturer.

5.

Place tool over connector. Center connector between the dies.

6.

Align jaw as necessary to ensure proper crimp. Position subject at a 90

O

angle to the tool.

KEEP HANDS AND ALL BODY PARTS AWAY FROM COMPRESSION OPERATION

7.

Turn power source “ON” and activate control valve to advance compression dies up to subject. Check tool alignment.

8.

Continue to advance until “pop off” is felt or heard and full pressure has been obtained.

9.

Return source to the “OFF” position and allow ram to retract completely.

10. Repeat procedure as required by compression sleeve or regulating authority.

11. Visually inspect crimp for correctness.

10

DAILY MAINTENANCE

The life, reliability, and safety of the tool is dependent on proper use and maintenance.

STORE THE TOOL PROPERLY . . . Before storing tools release pressure so that the crimping jaw fully retract. This protects the operating ram from moisture and condensation.

NOTE:

When the tool has been stored for extended period of non-use, the tools should be activated approximately every 3 weeks to keep o-rings and seals lubricated.

Clean and inspect all surfaces including head, ram, body and coupler.

WARNING:

Head may cut or pinch. Please use extreme caution.

Worn or damaged parts may malfunction during operation, causing more extensive damage to the tool and/or severe injury to the operator or bystander.

All parts must be replaced with new parts if signs of wear or damage are evident.

DO NOT MAKE ADJUSTMENTS TO THE TOOL . . . There are no adjustments on this tool which can be made in the field. If a tool becomes inoperative and the instructions in this booklet do not correct the malfunction have the tool serviced by RELIABLE

EQUIPMENT or an authorized service provider.

Keep Label Set clean and legible. Replace decals when necessary.

Manufacturer recommends regular testing for proper pressure and operation.

Test at least every 6 (six) months, test more often under heavy usage.

This tool requires well-trained experienced personnel for major repairs, adjustments or maintenance. Complete disassembly is not recommended. Return the unit to an

authorized dealer for total disassembly and/or repair. It is suggested that tools requiring repairs be returned to Reliable Equipment for correction unless overall local conditions are adequate and service training has been provided. Reliable Equipment is set up to provide quick maintenance and overhaul service. Contact your Reliable

Equipment representative if service is required.

All maintenance or disassembly should take place on a flat, clean work surface covered with towels or wipers so as to have a clean space for the disassembled parts.

Inspect each part during disassembly for wear, scratches, and cuts. Discard the worn or damaged parts and replace with new factory authorized parts.

O-rings are sensitive to sharp edges. Inspect closely for cuts or damage. A small cut will cause a leak. When assembling or disassembling O-rings, use hydraulic fluid as a lubricant to help disassembly or installation.

NOTICE:

When disposing of hydraulic fluid, parts or components observe all federal, state, and local guidelines.

11

REL-46

- R E M O T E H E A D PA R T S L I S T

ITEM QTY PART # DESCRIPTION

1

9

10

6

7

4

5

8

2

3

15050

K5054

15004

15101

15102

15125

15013

15014

15015

15018

15199

1

1

1

1

1

1

1 *

2 *

2 *

4

* ITEMS INCLUDED IN SEAL KIT

CRADLE

DIE RETAINER KIT (2 PINS, 2 NUTS, 2 SPRINGS)

HEAD ( SUPPLIED BY RELIABLE)

LOWER HOUSING

RAM

EXTENSION SPRING ASSY

WIPER

O-RING

BACKUP RING

SCREW ( CRADLE )

SEAL KIT

NOTE: Keep Label Set clean and legible. Replace decals when necessary.

WARNING

BEFORE USING THIS PRODUCT

READ THE SAFETY WARNINGS

and recommended practices described in the manual. Failure by the operator to read and fully understand the warnings will leave this person unqualified to use and operate the tool.

Failure to observe all warnings and instructions could result in property damage, severe personal injury, and/or death.

WARNING

KEEP BODY PARTS OUT

OF COMPRESSION ZONE

Do not operate without dies.

REL-SM REL-SM

IF YOU HAVE QUESTIONS REGARDING THE REPAIR AND MAINTENANCE OF THIS TOOL

CONTACT RELIABLE EQUIPMENT OR YOUR RELIABLE EQUIPMENT REPRESENTATIVE.

12

13

REL-46

PARTS DRAWING # 1

HEAD ASSEMBLY

Date Parts or Service Required

If you have any questions regarding the information found in this manual please contact RELIABLE EQUIPMENT at the address, phone or fax numbers shown below.

92 Steamwhistle Drive Ivyland, PA 18974

Phone: 800-966-3530 Fax: 215-357-9193

Visit us on the web at www.Reliable-Equip.com

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