Cembre RHU 1000 Owner's manual

1
SINGLE & DOUBLE ACTING
HYDRAULIC PRESSHEAD
RHU1000
ENGLISH
OPERATION AND MAINTENANCE MANUAL
18 M 036 E

2
2
3
4
1
1 2 3 4
TG. 0356
Before using the tool, carefully read the instructions in this manual.
When operating the tool, keep hands away from the danger zone.
Operate only with dies and product inserted.
DANGER
The user should be properly
trained in the correct
procedures required for work
on or around electrical lines.
ELECTROCUTION
HAZARD
Operation and safety methods
may vary in accordance with
the guidelines of each utility.
For your own safety, ensure
that you fully comply with all
safe operations guidelines
required by your respective
power utility.
BEFORE USING THIS TOOL 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 unquali-
fied to use and operate the tool. Failure to observe all
warnings and instructions could result in property
damage, severe personal injury or death.
WARNING
CAUTION
TG. 0934
170 mm
40 mm
TG. 0934
TG. 0935
Before operating make sure the
latch is secure. Latch improperly
secured can cause tool damage
and personal injury.
CAUTION
25 mm
50 mm
TG. 0935
Keep labels clean and legible, replace if necessary.
TG. 0934
TG. 0935
TG. 0356
TG. 0947
ONLY OPERATE WITH
THE TOP DIE HOLDER
IN PLACE
WARNING
25 mm
50 mm
TG. 0947
TG. 0947
WARNING LABELS

3
200
32 1
9
43
38
35
202
48
13
42
1 HOLDER HANDLE 42 DIE RETAINING PIN
9 VENT PLUG (for single acting) 43 DIE RELEASE PIN
13 MALE QUICK RELEASE COUPLER 47 LIFTING EYE (for suspended use)
32 LIFTING HANDLE 48 SAFETY NUT
35 DIE HOLDER LATCH 200 TOP DIE HOLDER
38 COUPLER PROTECTION HANDLE 202 RAM
Description:
47

4
– Use this tool for its intended purpose only.
– Inspect tool before use, replace any worn or damaged parts.
– Inspect pump hydraulic hoses and couplings before each use.
– Clear work area.
– Operating & Safety procedures may vary in accordance with the working guide lines
established by each utility or contractor.
– For your own safety, ensure that you fully comply with all“safe operation” practices required
by your employer.
– To protect from ELECTRICAL SHOCK HAZARD, always wear the necessary cloting & equipment
and follow the required safety practices.
Failure to follow these rules may result in serious personal injury or death.
– Before connecting or disconnecting the presshead always disconnect pump / power source
and switch to OFF.
– Before connecting the presshead always inspect hoses and couplings.
Always wear eye protection to avoid injury from flying debris or hydraulic oil leaks.
– To avoid tool damage or severe injury, worn or leaking parts must be repaired or replaced,
leakage is a sign of deterioration in component parts.
GENERAL SAFETY
1. GENERAL CHARACTERISTICS
– Application range: suitable for installing compression sleeves and lugs on ACSR and ACAR full
tension, substation and transmission connections.
– Supply: Operable from a single or double acting 10,000 psi hydraulic power source.
– Crimping force: ................................................................................................. 1100 kN (123 sh ton)
– Max. operating pressure: ............................................................................. 700 bar (10,000 psi)
– Oil necessary (displacement):...................................................................... 462 cm3 (28.2 cu.in.)
– Ram stroke: ......................................................................................................... 30 mm (1.18 in.)
– Weight: (without dies)..................................................................................... 50,7 kg (111.5 lbs)
– Dimensions: ....................................................................................................... Ref. to page 15
– Type of dies: RHU1000 presshead can accepts most 100 ton semi-circular type dies currently
used with Alcoa, Burndy, and other 100 ton presses.

5
2.1) Setting
The head must be transported by two people, always using the handles provided.
Always use RHU1000 on a level and stable surface, e.g the ground. Alternatively, the head may be
suspended for use via the lifting eye (47) (refer to § 2.7).
The head is equipped with a “self-lock” quick male coupler and can be connected to Cembre
single acting hydraulic pumps developing 700 bar (10,000 psi) pressure.
Otherwise it’s possible to convert the presshead for use with a double acting pump developing 700
bar (10,000 psi) (refer to § 4).
- SINGLE ACTING COMPRESSION
– Connect the pump hose to the presshead which is equipped with a“self-lock” quick male coupler
and can be connected to a Cembre hydraulic pump developing 700 bar (10,000 psi) pressure.
- DOUBLE ACTING COMPRESSION
– Convert the head following instructions as per § 4.
– Check that the power source develops 700 bar (10,000 psi) pressure.
Pay attention to the correct connection of the hoses to the pressure and return ports.
– Connect the return hose to the return port on the power source, then to the female upper coupler
on the head. Connect the pressure hose to the lower male coupler on the head, then to the pressure
port on the power source.
Hydraulic flow reversal causes malfunction in operation and may result in severe injury or death.
2.2) Die insertion/extraction
– Select the appropriate die set as recommended by
the lug or sleeve manufacturer.
– Insert one die in the upper seat of the top die holder
(200) until it is locked; to ease the die insertion, keep
the pin (43a) depressed.
– Likewise, insert the other die into the seat on the
ram (202) by pressing the pin (43b).
Never pressurise the head without
top die holder and dies in place as
serious damage and /or personal
injury may result.
43a
200
43b 202
crimping die
To remove dies, take them off
their guides by pushing relevant
pins (43a and 43b).
2. INSTRUCTIONS FOR USE

6
2.3) Ram advancing and die positioning
– Locate the connector between the dies at the
crimp position, if nesessary open the head
following instructions as per § 2.6.
– Operate the pump until the dies touch the
connector.
Make sure that dies are exactly positioned on
desired crimp point, otherwise re-open dies
following instructions as per § 2.5 and reposition
the connector.
Before starting the crimping operation
make sure the top die holder is in place and
latch is secure.
Operating without top die holder or latch
improperly secured can cause tool damage
and personal injury.
2.4) Crimping
– Operate the pump to advance the ram (202) until
the die faces touch.
It is recommended to continue pumping until the
maximumpressurevalveofthe pumpis activated
and a “click” is heard.
– Re-open the dies (see § 2.5) and repeat steps
above as necessary following crimping sequence
recommended in the installation instructions
of the connector manufacturer.
Lower pressure may reduce tonnage achieved and reduce crimp integrity. Higher operating
pressure may cause structural failure and / orpersonal injury.
2.5) Die opening
– Fully discharge the oil pressure from the release device of the pump to retract the ram and release
the crimped connector; if necessary open the top die holder to remove the connector (see § 2.6).
202
connector
upper die
conductor
lower die

7
2.6) Head opening
When required, the upper part of the head can be removed
to permit an easy introduction of the connector or removal
of it after crimping.
Proceed as follows (with reference to Fig. a):
1 Hold the handle (1) and pull the latch (9).
2 Turn the top die holder (200) through 90 degrees.
3 Remove the top die holder (200).
– Insert the conductor into the connector and introduce the
connector into the head.
1 Relocate the top die holder (200) (Refer to Fig. b).
2 Pull the latch (9).
3The holder automatically turns into the locking position
(Refer to Fig. c).
CLICK 2
2
1
3
1
3
CLICK
2
2
1
3
1
3
CLICK
2
2
1
3
1
3
connector
9
200
1
9
200
Before crimping operations, check
that the head is correctly reassembled
and latch (9) is correctly located.
Fig. a
Fig. b
Fig. c
conductor

8
2.7) Lifting eye installation
To use the head in suspension mode for aerial operations, it is necessary to use the lifting eye:
– Remove lifting eye from case lid.
– Screw locking nut fully onto lifting eye.
– Turn the head upside down and screw
lifting eye completely into its seat, then
tighten locking nut against the head.
Before lifting the head, make sure the lifting eye is fully secured otherwise tool damage,
personal injury or death may occur.
Never stand under the suspended head.
Use a safety hook to lift the head and follow
all safety rules required by your employer.
UPPER
PLUG VENT
COUPLER
FEMALE
COUPLER Q38-F*
FEMALE
COUPLER
NIPPLE
3/8” NPT *
UPPER
PLUG VENT
COUPLER
FEMALE
COUPLER Q38-F*
FEMALE
COUPLER
NIPPLE
3/8” NPT *
Lifting eye
Lifting eye
locking
nut
Safety
hook
weight (without dies):
50,7 kg (111.5 lbs)

9
Before starting any maintenance operations, always depressurise hydraulic system and
disconnect the head from the hose pump.
Compliance with the following points should help to maintain the optimum performance of the tool.
The head is robust and requires very little daily maintenance.
The parts must be replaced if signs of wear or damage are evident.
All maintenance or disassembly should take place on a flat, clean work surface covered if necessary so
as to have a clean space for the disassembled parts.
Inspect each part during disassembly for wear, scratches, cuts and always replace with new Cembre
original parts. Worn or damaged parts may malfunction during head operation.
3.1) Accurate cleaning
Dust, sand and dirt are a danger for any hydraulic device.
Avoidputting thehead on muddyor dustygroundasdirtparticlesmayscoretheramand createoilleaks.
Every day, after use, the head must be wiped with a clean cloth, taking care to remove any residue,
especially around moving parts.
Occasionally lubricate die stop pins (42 and 43) and latch (9); these parts must also be cleaned and
lubricated to prevent sticking.
3.2) Replacement of the supplied automatic coupler
To replace the automatic coupler, proceed as follows:
– Remove the old coupler.
– Carefully clean the thread to remove the old sealant.
– Apply Teflon tape to the thread.
– Fit the new automatic coupler and tighten to
30 Nm (22 lbf ft).
3.3) Storage
The head must be always lifted and trasported by
two people. When not in use, store and transport
the head in the specific steel case to prevent dam-
age. Inside the case lid are specific clips to locate
the lifting eye.
VAL1000 steel case:
weight 12 kg (26.5 lbs).
size 334x244x435 mm (13.1x9.6xh17,1in.)
Total weight (presshead + steel case):
63 kg (138 lbs) without dies.
Lifting eye
VAL 1000
Steel case
RHU1000
Presshead
3. MAINTENANCE

10
Before starting conversion always check that the ram is completely retracted and the pump
hose is disconnect from the head.
- FROM SINGLE TO DOUBLE ACTING -
– Remove upper plug vent from the head, insert
female coupler Q38-F and nipple 3/8” NPT,
using appropriate pipe thread sealant and tighten
to 30 Nm (22 lbf ft).
– Connect appropriate high pressure hoses from
a suitable power source (10,000 psi) and operate
as a double acting hydraulic tool.
UPPER
PLUG VENT
COUPLER
FEMALE
COUPLER Q38-F*
FEMALE
COUPLER
NIPPLE
3/8” NPT *
- FROM DOUBLE TO SINGLE ACTING -
– Remove female coupler and nipple from the head.
– Tip the head to pour oil from upper cylinder into a
suitable container.
– Insert supplied vent using appropriate pipe thread
sealant and tighten to 30 Nm (22 lbf ft).
Check that the oil is completely drained, before inserting
the plug vent.
– Connect appropriate high pressure hose from a suitable
power source and operate as a single acting hydraulic tool.
SINGLE
ACTING
DOUBLE
ACTING
LOWER PRESSURE PORT:
ram advancing
UPPER RETURN PORT:
ram returning
* optional accessories:
Q38-F code 6060126
NIPPLE code 6525090
4. CONVERSION INSTRUCTIONS

11
NOTICE: This tool has undergone a magnetic particle inspection (MAGNAFLUX test) and is certified in
accordance with ASTM-E1444, MIL-STD-271F, MIL-STD-1907.
SAFETY PRECAUTIONS:
A Non-Destructive Testing (NDT) should be performed by a suitably qualified body after the first two
years of service, then annually, and the evidence of the execution marked on the tool, local to its serial
number with the date shown as MMYY.
Notwithstanding the above, the tool should be regularly inspected and serviced particularly if it is
subject to intensive use.
6. SPARE PARTS LIST

12
▲
Torque setting
Nm Lbf ft
13 30 22
10 20 14.8
▲
▲
15
16
39
40
32
33
34
18
49
11
7
8
4
2
6
5
13
20
22
14
17
24
14
52
52
43
20
21
27
27
1
28
45
3
35
36
37
29
25
21
22
42
19
10-3
10
41 42
44
43
44
41
26
5
9
38
30
31
202
200
201
Tool serial number
47 48
50
51
53

13
▲
Torque setting
Nm Lbf ft
13 30 22
10 20 14.8
▲
▲
15
16
39
40
32
33
34
18
49
11
7
8
4
2
6
5
13
20
22
14
17
24
14
52
52
43
20
21
27
27
1
28
45
3
35
36
37
29
25
21
22
42
19
10-3
10
41 42
44
43
44
41
26
5
9
38
30
31
202
200
201
Tool serial number
47 48
50
51
53
TABLE 1

14
The items marked "K" are those
Cembre recommend replacing
if the tool is disassembled.
When ordering spare parts always
specify the following:
- code number of item
- name of item
- type of tool
- serial number of tool
TABLE 1
The guarantee is void
if parts used are not
Cembre original spares.
Code N° DESCRIPTION
- 2 FORK 1
6232683 4 TG.0926 TOOL NAMEPLATE 1
6900426 5 M8x30 SCREW 2
6100043 6 KEY 2
6003936 7 SCRAPER 1 K
6362099 8 SEAL 1 K
6002248 9 PLUG VENT 1
6650118 11 ø2,5x3,5 RIVET 2
6362100 14 SEAL V1 2 K
6525072 15 3/8"-1/4"MM NPT NIPPLE 1
6340121 16 PLUG VENT 1
6120110 17 BOTTOM PLUG 1
6232006 18 TG.0356 WARNING LABEL 1
6232692 19 TG.0935 WARNING LABEL 1
6900558 20 SCREW 2
6640286 21 Ø6 NL WASHER 2
6362034 22 SEAL V1 2 K
6040132 52 BACK-UP RING 2 K
6520443 24 COMPLETE RAM SPRING 1
6490075 32 UPPER HANDLE 2
6900347 33 M8x20 SCREW 8
6640199 34 Ø8 SCHNORR WASHER 8
6490076 38 LOWER HANDLE 2
6900337 39 M6x14 SCREW 4
6640112 40 Ø6 SCHNORR WASHER 4
6370022 47 LIFTING EYE 1
6180990 48 M20 NUT 1
6232691 49 TG.0934 WARNING LABEL 1
6880057 50 D.5 STEEL CABLE
6506653 200 TOP DIE HOLDER ASSY 1
1
6490048 200 1 HANDLE & SCREWS 1
6180301 200 3 M8 NUT 1
6900276 200 27 M8x8 SCREW 1
6520595 200 28 SPRING 1
6080049 200 29 BUSH 1
- 200 30 ADAPTER SUPPORT 1
6640124 200 31 Ø8,3 WASHER 1
6560187 200 35 LATCH 1
6600023 200 36 LOCKING PIN 1
6520561 200 37 SPRING 1
6900427 200 45 M8x65 SCREW 1
6506651 200 201 UPPER ADAPTER ASSY 1
- 200 201 26 UPPER ADAPTER 1
6900276 200 201 27 M8x8 SCREW 2
676041
6
200 201 41 POSITIONING PIN 1
6620338 200 201 42 DIE RETAINING PIN 1
6620444 200 201 43 DIE RELEASE PIN 1
6520559 200 201 44 SPRING 1
6620542 202 COMPLETE RAM 1
6895058 202 10 COMPLETE VALVE 1
6362102 202 10 3 SEAL V1 1
- 202 25 RAM 1
6760416 202 41 POSITIONING PIN 1
6620338 202 42 DIE RETAINING PIN 1
6620444 202 43 DIE RELEASE PIN 1
6520559 202 44 SPRING 1
Item Qty
6232704 51 TG.0947 WARNING LABEL 1
12K4512 rev. D
6800186 53 PROTECTION CAP 1
6060120 13 1Q14-MS QUICK COUPLER + CAP

15
DIMENSIONS mm (inches)
184,5 (7.2)
278 (10.9)
414 (16.3)
In the case of a breakdown, contact our Area Agent who will advise you on the problem and give
you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible,
include a copy of the Test Certificate supplied by Cembre with the tool or, if no other references are
available, indicate the approximate purchase date and the tool serial number.
5. RETURN TO Cembre FOR OVERHAULS

16
Cembre Ltd.
Dunton Park
Kingsbury Road, Curdworth - Sutton Coldfield
West Midlands B76 9EB (UK)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembre.co.uk
Cembre S.p.A.
Via Serenissima, 9
25135 Brescia (Italia)
Telefono: [phone]
Telefax: [phone]
E-mail: [e-mail]
www.cembre.com
Cembre S.a.r.l.
22 Avenue Ferdinand de Lesseps
91420 Morangis (France)
Tél.: [phone] - Fax: [phone]
CS 92014 - 91423 Morangis Cédex
E-mail: [email protected]
www.cembre.fr
Cembre España S.L.U.
Calle Verano 6 y 8
28850 Torrejón de Ardoz
Madrid (España)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembre.es
Cembre GmbH
Heidemannstraße 166
80939 München (Deutschland)
Telefon: [phone]
E-mail: [email protected]
www.cembre.de
Cembre Inc.
Raritan Center Business Park
300 Columbus Cicle - Suite F
Edison, New Jersey 08837 (USA)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembreinc.com
www.cembre.com
IKUMA GmbH & Co. KG
Boschstraße 7
71384 Weinstadt (Deutschland)
Telefon: [phone]
Telefax: [phone]
E-mail: [email protected]
www.ikuma.de
cod. 6261352 This manual is the property of
Cembre:
any reproduction is forbidden without written permission.