Reliable Equipment & Service REL-4000SA Manual

1
DISTRIBUTED BY
OPERATORS’ GUIDE
REL-4000SA Manual 05-11
WARNING
All information found in this guide
must be read and understood
before use or testing of tool.
Failure to read and understand warnings
and safe handling instructions could result in
severe personal injury and or death.
REL-4000SA
HYDRAULIC 4” CUTTING TOOL
NOTICE
Sizes, weights and tool specifications listed in
this manual are subject to change without notice.
Pleaseconsultfactoryforinformationandupdates.
FULL 4 INCH
COPPER AND ALUMINUM
CUTTING CAPACITY
HIGH PRESSURE
FEMALE COUPLER
INSTALLED
The REL-4000SA
cutter accommodates
copper and aluminum
conductors up to 4 inches.
The body and handle were provide comfort,
and protect the operator from inadvertent
contact with the blade or operation.
The hardened steel blades will provide a
clean cut with minimal distortion.
A ring has bee added to aid in bringing the
tool to the cut, with less operator strain.
LIFTING
RING

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CAU-
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.
DISTRIBUTED BY

3
TABLE OF CONTENTS
REGISTRATION
UPON RECEIPT OF THIS TOOL, COMPLETE THE REGISTRATION BELOW.
COMPANY _____________________________________________________________
ADDRESS _____________________________________________________________
________________________________________________________________________
PHONE _______________________ FAX____________________________________
SERIAL NUMBER _______________________________________________________
DATE OF PURCHASE ___________________________________________________
DEALER NAME _________________________________________________________
THIS SYMBOL INDICATES ITEMS OF EXTREME IMPORTANCE.
Safety of user and others may be in jeopardy if these instructions
are not read and understood.
DISTRIBUTOR INFORMATION ................................................................. 2
TABLE OF CONTENTS ............................................................................. 3
REGISTRATION ......................................................................................... 3
DESCRIPTION ........................................................................................... 4
TOOL SPECIFICATIONS ........................................................................... 4
SAFETY INFORMATION AND WARNINGS............................................5-9
OPERATING INSTRUCTIONS ................................................................... 9
PARTS DIAGRAM ................................................................................... 10
PARTS LIST ............................................................................................. 11
DAILY MAINTENANCE............................................................................. 12
LABELS.................................................................................................... 12
MAINTENANCE RECORDS..................................................................... 13
CONTACT INFORMATION ...................................................................... 14

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FULL 4 INCH
COPPER AND ALUMINUM
CUTTING CAPACITY
REL-4000SA
HYDRAULIC 4 INCH CUTTING TOOL
The REL-4000SA single acting hydraulic
cutterhas beendesigned toaccommodate
copper and aluminum conductor up to
4 inches in diameter.
The body and handle have been designed
to provide comfort, and to protect the
operator from inadvertent contact with
the blade or mechanism.
The hardened steel blades will provide
a clean cut with minimal distortion.
301 Ivyland Road Warminster, PA 18974
Phone: [phone] Fax: [phone]
Visit us on the web at www.Reliable-Equip.com
REL-4000SA
HYDRAULIC 4” CUTTING TOOL
SPECIFICATIONS
Weight: 17.5 lbs.
Size: 15.6” x 10” x 4”
System Hydraulic - 10,000 psi max.
Max. Cut 4 inch dia. (Cu. or Al.)
DO NOT CUT STEEL
HIGH PRESSURE
COUPLER INSTALLED
LIFTING
EYE

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WARNING
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.
Eye Protection
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.
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.
Hard Hat
WARNING
Always wear a hard hat to avoid injury
from falling debris. 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.
Foot
Protection
Always wear foot protection.
Failure to do so can result in serious
personal injury.
WARNING
Protective
Gloves
WARNING
Always wear protective gloves.
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.

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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.
SAFE OPERATION & CARE
USE THIS TOOL FOR ITS INTENDED PURPOSE ONLY
Any other use can result in 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
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.
WARNING

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HOSES AND FITTINGS
There exists the potential for shock in using anything other than
certified non-conductive 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 before 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
SERIOUS BURN HAZARD
HOT SURFACES MAY CAUSE SERIOUS BURN OR INJURY
The hydraulic cylinder may be hot during and after operation.
CAUTION: HYDRAULIC FLUID MAY CAUSE SERIOUS BURNS
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
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

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GENERAL SAFETY
USE ALL APPROPRIATE AND APPLICABLE PERSONAL SAFETY EQUIPMENT as required by
the operating company.
ALWAYS INSPECT TOOL for wear or deterioration every day. Replace all parts that show
signs of wear or damage.
KEEP ALL PARTS OF THE BODY AWAY from moving parts of the tool.
KEEP HANDS OUT FROM BETWEEN FIXED AND MOVING BLADES AT TOOL HEAD.
HANDS SHOULD BE OUTSIDE DANGER ZONE PRIOR TO ACTIVATING BLADE.
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.
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 SAFETY RULES FOR A PARTICULAR JOB CLASS
FAILURE TO HEED THESE WARNINGS COULD RESULT IN
PROPERTY DAMAGE, SERIOUS PERSONAL INJURY OR DEATH.
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.
WARNING
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.

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REL-4000SA OPERATION
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.
(Refer to GENERAL SAFETY on page 8)
Before cutting, ensure that material being cut is within the capacity listed for this tool.
Tool must be used in conjunction with a hydraulic system rated at, and adjusted to, 10,000 psi.
Any system not operating at 10,000 psi may cause damage to the tool and result in serious
injury to the operator.
Connect the tool head to the control valve or hose set. ( Refer to warnings on page 6 & 7 )
Insert material between cutter head and blade.
The material to be cut MUST be at a 90Oangle to the blade. This will ensure a proper cut
with minimal distortion. Severe blade damage may occur if material is cut at any other angle.
Operate pump or valve to slowly advance blade. If a hold feature is available, check for proper
alignment ( 90Oangle) of blade and material being cut.
Continue until cut is complete.
Return source to the OFF/RETRACT position and allow movable blade to retract completely.
Consult your supervisor, safety personnel, or RELIABLE EQUIPMENT if you have any
questions regarding the safe operation of this tool.
Do not cut live conductors.
Hardened metals may fly when severed.
Take necessary precautions. Wear safety glasses.
Keep all body parts away from cutting blades and moving parts.
WARNING
Failure to follow these rules can result in serious personal injury or death.
WARNING
CUTTING DANGER
This hydraulic cutting tool can cut, dismember 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 personal injury
and/or death.

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REL-4000SA-CUTTING TOOL
PARTS DRAWING

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ITEM PART NO. QTY DESCRIPTION
1 R52001 1 HOUSING
2 R52002 2 BLADE
3 R52003 1 PULL YOKE
4 R52004 1 CYLINDER
5 R52005 1 RAM
6 R52006 1 BLADE GUIDE
7 R52007 1 CAP
8 R52008 1 LOWER DISC
9 R52009 1 LOWER DISC ROD
10 R52010 1 INNER SPRING
11 R52011 1 MIDDLE SPRING
12 R52012 1 OUTER SPRING
13 R52013 1 CENTER PIN
14 R52014 2 OUTER PIN
15 R52015 3 HOUSING SCREW
16 R52016 1 RAM LOCKING SCREW
17 R52017 2 CENTER PIN RETAINING RING
18 R52018 4 OUTER PIN RETAINING RING
19 R52019 1 * CYLINDER O RING
20 R52020 1 * CYLINDER BACKUP RING
21 R52021 1 * RAM O RING
22 R52022 1 * RAM BACKUP RING
23 R52023 1 * CAP FACE O RING
24 R52024 1 * CAP SIDE DUST SEAL
26 R52026 1 LOWER DISC RETAINING RING
27 R52027 1 LOWER DISC SCREW
28 R52028 4 BLADE GUIDE SCREW
29 R52029 1 HANGER
30 R52030 1 EYELET ASSEMBLY
31 R52031 1 ROLL PIN
35 R52035 4 BUSHING
R36023 1 GRIP, RUBBER (NOT SHOWN)
R
52100 SEAL KIT * ITEMS INCLUDED IN SEAL KIT
PARTS LIST - REL-4000SA
4” SINGLE ACTING HYDRAULIC CUTTING TOOL
Contact RELIABLE EQUIPMENT at 800-966-3530 if you have any
questions related to the instructional information found in this manual.

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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.
REL-SM
WARNING
DANGER
BLADE
CLOSES
NOTE: Keep Label Set clean and legible. Replace decals when necessary. Part #RL52000
RELIABLE EQUIPMENT & SERVICE CO., INC.
92 Steamwhistle Drive • Ivyland, PA 18974 • USA
Phone: [phone] • Fax: [phone]
MODEL: REL-4000SA
MAX. PRESSURE: 10,000 PSI
SERIAL NO.: ____________
YEAR: ___________
Complete disassembly is not recommended. Return the unit to an authorized dealer
for total disassembly and/or repair.
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.
IMPORTANT: The greatest cause of hydraulic system failure is dirt.
Prevent the introduction of foreign matter into the unit via hydraulic fluid,
dirty connections or accumulation of sediment.
DAILY MAINTENANCE
The life, reliability, and safety of the tool is dependent on proper maintenance.
Clean all surfaces including head, blade, couplers (if coupled), threads, and handles.
Inspect for wear and damage. Worn or damaged parts may malfunction during operation.
All parts must be replaced with new parts if signs of wear or damage are evident.

13
Date Parts or Service Required
Maintenance Records

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301 Ivyland Road Warminster, PA18974
Phone: [phone] Fax: [phone]
Visit us on the web at www.Reliable-Equip.com
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.