Reliable Equipment & Service REL-750DM Manual
1
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OPERAOPERA
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OPERATORS’TORS’
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GUIDEGUIDE
GUIDEGUIDE
GUIDE
REL-750DM Manual 04-15
RELIABLE EQUIPMENT & SERVICE CO., INC.
301 Ivyland Road • Warminster, PA 18974 • USA
Phone: 215-357-3500 • Fax: 215-357-9193
MODEL: __________________________________
MAX. PRESSURE: _________________________
SERIAL NO.: ______________________________
YEAR: ___________________________________
NOTICENOTICE
NOTICENOTICE
NOTICE
Sizes, weights and tool
specifications listed in
this manual are subject
to change without notice.
Please consult factory for
information and updates.
WARNINGWARNING
WARNINGWARNING
WARNING
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.
REL-750DM
6.2 TON MANUAL HYDRAULIC
DIELESS CRIMPING TOOL
Compatible with Anderson and
equivalent dieless connectors.
2
3
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
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............................................................ 3
REGISTRATION .................................................................................... 3
TABLE OF CONTENTS......................................................................... 4
TOOL SPECIFICATIONS
REL-750DM - MANUAL HYDRAULIC
6.2 TON DIELESS COMPRESSION TOOL........................... 5
SAFETY INFORMATION AND WARNINGS.................................... 6-7
OPERATING INSTRUCTIONS ......................................................... 8-9
DAILY MAINTENANCE ....................................................................... 10
GENERAL MAINTENANCE ................................................................ 10
LABEL SET .......................................................................................... 11
REL-750 DM - PARTS DRAWING #1 HEAD ASSEMBLY ..................... 12
REL-750 DM - PARTS DRAWING #2 FIXED HANDLE ASSEMBLY ..... 13
REL-750 DM - PARTS DRAWING #3 PUMP HANDLE ASSEMBLY ..... 14
REL-750 DM - PARTS LIST ................................................................. 15
MAINTENANCE RECORDS ............................................................... 16
CONTACT INFORMATION ................................................................. 16
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.
5
301 Ivyland Road • Warminster, PA 18974
Phone: 800-966-3530 • Fax: 215-357-9193
Visit us on the web at www.Reliable-Equip.com
REL-750DM
6.2 TON MANUAL HYDRAULIC
DIELESS CRIMPING TOOL
Compatible with Anderson and
equivalent dieless connectors.
This REL-750DM compression head has
been designed to crimp Anderson type and
equivalent connectors manufactured to
ANSI C119.4.
This model features a connector range up to
750 MCM and a 1.5 inch jaw opening providing
ample space for easy die positioning. A two-
stage advance piston. The first stage brings
the crimp to the connector quickly, while the
second stage provides the power to make the
connection. The flip top design and 180O swivel
head permit simple tool positioning, while the
pull-pin closure will provide a safe positive lock.
FEATURES:
6.2 Ton output
Compatible withAnderson
& equivalent dieless connectors.
Flip top design and rotating head provide
easy placement around crimp.
Two stage pumping system
Eliminate the need for dies under
acceptable dieless applications.
Connector range from #10 to 750 MCM
Copper andAluminum.
Carrying case included.
SPECIFICATIONS
Length 19.5“ Width 7.5“ Weight 9.5 lbs.
Pressure 6.2 tons @ 10,000 psi (manual)
Capacity Dieless connector range from
# 10 to 750 MCM CU & AL
6
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
WARNING
Always wear foot protection.
Failure to do so can result in serious
personal injury.
Skin
Irritation
WARNING
WARNING
Protective
Gloves
Always wear protective gloves
Failure to do so can result in serious
personal injury.
Hydraulic oil may cause irritation.
Use care to prevent contact with skin.
In case of accidental contact, wash
affected area immediately
7
GENERAL SAFETYGENERAL SAFETY
GENERAL SAFETYGENERAL SAFETY
GENERAL SAFETY
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
COMPRESSION DANGER
This manual hydraulic crimping tool can injure and/or disable.
KEEP ALL PARTS OF THE BODY AWAY FROM MOVING PARTS.
Failure to observe this warning could result in serious injury
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.
KEEP HANDS OUT FROM BETWEEN CRIMPING NODES AT TOOL HEAD.
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.
8
OPERAOPERA
OPERAOPERA
OPERATIONTION
TIONTION
TION
Read entire manual prior to using this tool. Refer to all safety cautions and warnings.
Observe all safety precautions and procedures required by the operating company.
1. Before crimping, ensure that subject is within the capacity listed for the tool. (see page 5)
Ensure that Burndy or Anderson 6 ton dieless type compression sleeves are being used.
WARNING: Crimping standard “H” Frame (Double Open Groove) connectors
WILL cause tool damage and void warranty.
2. Retract compression nibs completely by pressing hydraulic release lever (A).
3. Release latch (B), and open tool head for simple
tool positioning around compression.
NOTE: Tool head rotates 180O to aid in proper
compression alignment with less fatigue.
4. Place subject in tool head (C) and close
latch securely.
NOTE: Failure to secure latch may result in
severe tool damage and/or personal injury.
5. Position subject at a 90O angle to the tool
compression head as shown in Figure 2 .
6. Pump handle (D) to advance compression nibs up to subject. Check tool alignment.
7. Pump handles until tool pressure builds up and “pop off” is felt.
Full crimping pressure has been obtained.
8.Retract compression nibs completely by pressing hydraulic release lever (A).
9. Repeat procedure as required by compression sleeve or regulating authority.
10. Visually inspect crimp for correctness.
B LATCH CHEAD
A RELEASE LEVER
STATIONARYHANDLE
PUMP
HANDLE
D
INCORRECT CORRECT
FIGURE 2
IF YOU HAVE ANY QUESTIONS REGARDING THE PROPER USE AND/OR OPERATION OF
THIS TOOL, CONSULT YOUR AREA SUPERVISOR, OR CONTACT RELIABLE EQUIPMENT.
9
CONDUCTOR PREPARATION
Strip insulation from the conductor, beign careful not to nick the strands. Use of a proper
insulation stripping tool, or using the “Pencil” shaving method is recommended. Thoroughly
clean the conductor by wire brushing until a bright shiny surface is obtained. All oxides and
foreign matter must be removed.
NOTE: Do not wire brush tin-plated conductors or tinned connectors.
INSTALLATION OF SLEEVE CONNECTORS
1. Place sleeve in the nib opening. (strip off insulation jacket where applicable using the center
band mark on the sleeve as a strip gauge.)
WARNING: Certain small service sleeve connectors can severely damage this tool by
becoming wedged between nibs of the tool head. Observe warnings and connector
positioning instructions as shown in Figure 2 on page 8
2. Using the pump handle, close the nibs until they contact the sleeve loosely.
3. Positioned the sleeve so that the nibs will make the first crimp adjacent to the center band mark.
4. Insert the conductor into the connector socket making sure that the conductor is pushed
fully in against the center barrier.
5. Actuate the Pump handle and the nibs will start compressing the sleeve. A positive trip
accompanied by a distinct “click” will occur when the crimp is fully made. Stop pumping.
6. Release the compressed nibs from the sleeve by compressing the release lever. The nibs
should open sufficiently to allow the sleeve to be repositioned for the next crimping operation.
7. After the second conductor has been installed and crimped, remove the tool by pulling the
latch pin out and opening the compression head.
INSTALLATION OF OPEN GROOVE (TAP) CONNECTORS
1. The tool head may be rotated to any desired position when the compression nibs are
fully retracted. Prior to installing tap conectors, the tool head should be positioned at an
angle which relieves awkwardness and operator fatigue.
WARNING: DO NOT OVEREXTEND your position by overreaching or unbalancing the
footing necessary to maintain physical control of your body and the tool.
2. Place the tape side of the connector full into the tool so that the open side in the
connector is facing between the top nib and either side nib. Close the nibs closely onto the
conector with the rapid advanced handle making sure that the positioning grooves mate
with two of the nibs. Follow the same instructions for compressing and releasing the
connector as previously described for sleeve connectors.
3. Place the main groove of the connector full into the tool with the open side facing
between the top nib and either side nib. Close the nibs loosely. Place the positioned
connector against the main conductor by applying firm pressure with the tool handles.
Compress the nibs for specificed number of crimps.
4. Remove the connector by retracting the nibs and opening the latch.
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.
10
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.
IF YOU HAVE QUESTIONS REGARDING THE REPAIR AND MAINTENANCE OF THIS TOOL
CONTACT RELIABLE EQUIPMENT OR YOUR RELIABLE EQUIPMENT REPRESENTATIVE.
GENERAL MAINTENANCEGENERAL MAINTENANCE
GENERAL MAINTENANCEGENERAL MAINTENANCE
GENERAL MAINTENANCE
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 pressur so that the
crimping nibs 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, latch mechanism, ram, and body.
Particularly avoid joint compounds from building up on the crimping nibs.
WARNING: Head and/or handles 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.
Check relief valve pressure setting regularly, using the optional pressure gauge.
(Optional - may be purchased from Reliable Equipment or your local Reliable representative).
Valve should be adjusted or replaced by a trained service technician if necessary.
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.
11
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.
ELECTROCUTION
HAZARD
The user should be properly
trained in the correct procedures
required for work on or around
electrical lines.
REL-SM
WARNING
Secure latch before operating.
Failure to secure latch can result in
severe tool damage and personal injury.
INCORRECT CORRECT
WARNING
KEEP BODY PARTS OUT
OF COMPRESSION ZONE
Secure latch before operating.
Failure to secure latch may result
in severe tool damage and/or
personal injury.
DO NOT OPERATE TOOL
SERIOUS TOOL DAMAGE AND/OR
PERSONAL INJURY MAY RESULT
12
REL-750 DM
PARTS DRAWING #1
HEAD ASSEMBLY
13
REL-750 DM
PARTS DRAWING #2
FIXED HANDLE
ASSEMBLY
14
REL-750 DM
PARTS DRAWING #3
PUMP HANDLE
ASSEMBLY
15
301 Ivyland Road • Warminster, PA 18974
Phone: 800-966-3530 • Fax: 215-357-9193
Visit us on the web at www.Reliable-Equip.com
Please consult RELIABLE EQUIPMENT with any parts questions.
16
Date Parts or Service Required
MAINTENANCE RECORDSMAINTENANCE RECORDS
MAINTENANCE RECORDSMAINTENANCE RECORDS
MAINTENANCE RECORDS
301 Ivyland Road Warminster, PA 18974
Phone: 800-966-3530 Fax: 215-357-9193
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.
Table of contents
