Reliable Equipment & Service REL-10-I Manual

OPERAOPERA
OPERAOPERA
OPERATT
TT
TORS’ORS’
ORS’ORS’
ORS’ GUIDE GUIDE
GUIDE GUIDE
GUIDE
Intensifier 1Manual 02-16
WARNINGWARNING
WARNINGWARNING
WARNING
All information found in this guide must be
read and understood before operation 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-10-I-SA
REL-10-I-SA/D
SINGLE & DOUBLE ACTING
HYDRAULIC 10,000 PSI
INTENSIFIER / VALVE
The NEW REL-10-I-SA/D single
& double acting control systems
provides a unique solution to your
high pressure tooling requirements.
REL-10-I
10,000 PSI INTENSIFIER
This system combines the
power of a high pressure
intensifier with the simplicity
of a fixed position three
way control valve.
This revolutionary intensifier will increase line
pressure to a maximum of 10,000 psi and is fully
compatible with all high pressure hydraulic
equipment. (i.e. Crimping, Cutting & Spearing Tools)
RELIABLE EQUIPMENT & SERVICE CO., INC.
301 Ivyland Road • Warminster, PA 18974 • USA
Phone: [phone] • Fax: [phone]
MODEL: REL-10-I & REL-10-I-SA
SOURCE PRESSURE: 2,000 PSI
INTENSIFIED PRESSURE: 10,000 PSI
SERIAL NO.: ____________
YEAR: ___________
NONO
NONO
NOTICETICE
TICETICE
TICE
Sizes, weights and tool specifications listed in this
manual are subject to change without notice.
Please consult factory for information and updates.

2
TABLE OF CONTENTS
Registration .................................. 2
Tool Quick Reference................ 3-4
General Safety Issues ............... 5-7
SPECIFICATIONS
General ......................................... 7
Pre-Operation ............................... 8
Hydraulic Fluids ........................... 8
Connections and Hoses............... 9
Operation (Single Acting) .......... 10
Operation (Double Acting)......... 11
MAINTENANCE
General ....................................... 12
Troubleshooting ......................... 13
Before Disassembly ................... 14
REGISTRATION
UPON RECEIPT OF THIS TOOL, COMPLETE THE REGISTRATION BELOW.
COMPANY __________________________________________________________
ADDRESS ___________________________________________________________
_____________________________________________________________________
PHONE _________________________ FAX ______________________________
SERIAL NUMBER ____________________________________________________
DATE OF PURCHASE ________________________________________________
DEALER NAME ______________________________________________________
Reservoir Clean & Fill ................ 14
Major Components (Fig. 1&2) . 15-16
External Assembly (Fig. 3) ........... 17
Motor Assembly (Figure 4) ........... 18
Pump Block Assy (Figure 5) .... 19-20
Drive Gear Assy (Figure 6) ........... 21
REL-DIR-VALVE........................... 22
Valve Assembly (Figure 7) ....... 23-24
Maintenance Record .................. 25
Phone, Fax & Address................ 24
This symbol indicates items
of extreme importance. Safety
of user and others may be in
jeopardy if these instructions
are not read and understood.
DISTRIBUTED BY

3
TABLE OF CONTENTS
Registration & Distributor Information.............................................................2
Table of Contents ..............................................................................................3
Tool Quick Reference (REL-10-I) ......................................................................4
Tool Quick Reference (REL-10-I-SA) ................................................................5
Tool Quick Reference (REL-10-I-SAD).......................................................... 6-7
General Safety Issues ................................................................................. 8-10
Pre-Operation ..................................................................................................11
Hydraulic Fluids ..............................................................................................11
Connections and Hoses (ALL MODELS) ......................................................12
Operation (REL-10-I-SA) .................................................................................13
Operation (REL-10-I-SAD Single Acting).......................................................14
Operation (REL-10-I-SAD Double Acting) .....................................................15
MAINTENANCE
General ............................................................................................................16
Before Disassembly ........................................................................................17
REL-10-I Drawings & Parts Lists (Fig. 1&2) ............................................... 18-19
REL-10-I Drawing & Parts List (Fig. 3) ...........................................................20
PVA-00L3 Control Valve Drawing & Parts List (Figure 4) ...............................21
Maintenance Record ......................................................................................22
Manufacturer Contact Information (Phone, Fax & Address) ........................22
THIS SYMBOL INDICATES ITEMS OF EXTREME IMPORTANCE.
Safety of user and others may be in jeopardy if these instructions are not
read and understood.
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

4
SPECIFICATIONS
HYDRAULIC SYSTEM ..................Open or Closed Center
MOTOR .......................................................... Gear Driven
OPERATING PRESSURE ........................ 1,400-2,000 psi
FLOW RANGE .................................................... 4-7 gpm
OPTIMUM OPERATING PRESSURE .. 1,800 psi @ 6 gpm
OUTPUT - FAST ADVANCE MODE ..............305 in. 3/min
OUTPUT - HIGH PRESSURE MODE.............. 30 in. 3/min
RELIEF VALVE SETTING .................... 4,000 - 10,000 psi
HIGH PRESSURE PORT ............................... 3/8 in. NPT
INLET PORT .................................................. 3/8 in. NPT
RETURN PORT ............................................. 3/8 in. NPT
SPECIAL FEATURES
HIGH PRESSURE COUPLER ............................. Included
ADJUSTABLE MOUNTING BRACKETS .............. Included
UL-BCA - MOUNTING BUCKET ......................... Optional
REL-10-I
INTENSIFIER
10,000 PSI
A SMALL A SMALL
A SMALL A SMALL
A SMALL TT
TT
TOOL FOR OOL FOR
OOL FOR OOL FOR
OOL FOR A BIG JOB!A BIG JOB!
A BIG JOB!A BIG JOB!
A BIG JOB!
This revolutionary intensifier will increase
line pressure to a maximum of 10,000 psi
and is fully compatible with all high
pressure hydraulic equipment. (i.e.
Crimping, Cutting & Spearing Tools)
In comparison to the Stage Pump's 75 to
185 moving parts, Reliable's Intensifier
with only 12 moving parts will provide
consistent, smooth operation and
simplicity of service, which was never
before available in it's costly and
complex counterpart.
301 Ivyland Road • Warminster, PA 18974
Phone: [phone] • Fax: [phone]
Visit us on the web at www.Reliable-Equip.com
SPECIAL FEATURES
1. H/P Quick-Disconnects
2. Folding Handle with 90O Stop
3. Adjustable Mounting Brackets
Height 4.50 in.
Length 5.25 in.
Width 4.25 in.
Weight 9.75 lb.
REL - 4 -IIncrease to 4,000 psi
REL - 6 -IIncrease to 6,000 psi
REL-10 -IIncrease to 10,000 psi

5
SPECIFICATIONS
HYDRAULIC SYSTEM ................ Open or Closed Center
MOTOR .........................................................Gear Driven
OPERATING PRESSURE ....................... 1,400-2,000 psi
FLOW RANGE .................................................... 4-7 gpm
OPTIMUM OPERATING PRESSURE ..1,800 psi @ 6 gpm
OUTPUT - FAST ADVANCE MODE ............. 305 in. 3/min
OUTPUT - HIGH PRESSURE MODE ............ 30 in. 3/min
RELIEF VALVE SETTING ................... 4,000 - 10,000 psi
HIGH PRESSURE PORT ............................... 3/8 in. NPT
INLET PORT................................................... 3/8 in. NPT
RETURN PORT .............................................. 3/8 in. NPT
SPECIAL FEATURES
HIGH PRESSURE COUPLER ............................Included
ADJUSTABLE MOUNTING BRACKETS .........Included
UL-BCA - MOUNTING BUCKET ......................Optional
REL-10-I-SA
SINGLE ACTING 10,000
PSI
The REL-10-I-SA provides quick advance
and retract for high pressure (10,000 psi) single
acting spring return tools, without the need for
additional H/P hoses, couplers or an in-line
control valve.
This system combines the power of a high
pressure intensifi er with the simplicity of a fi xed
position three way control valve.
The REL-10-I intensifier will increase line
pressure to a maximum of 10,000 psi and is
fully compatible with all high pressure hydraulic
equipment.
The PVA-00L3 single-acting control valve,
provides 3-way control (Advance, Neutral,
Retract) direct from the high pressure source.
Together this intensifi er/valve package allows
return oil to bypass the intensifi er and return
directly to the tank (return) line, increasing tool
speed and performance.
SPECIFICATIONS - HYD. POWER SOURCE
200 PSI back pressure is the maximum agreed standard for the Hydraulic Tool Manufacturers Association (HTMA).
1. Maximum fluid temperature must not exceed 140OF (60OC) at the maximum expected
ambient temperature. A sufficient oil cooling capacity is needed to limit the fluid temperature.
2. Maximum fl ow must not exceed 8 GPM. Install a fl ow meter in the return line to test the rate of fl ow
in the system before working the tool.
3. Pressure relief valve must not exceed 2,200 PSI. The pressure relief valve must be located in the
supply circuit between the pump and the intensifi er to limit excessive pressure to the tool.
Any hydraulic power source used with this unit must meet the requirements above.
REL-10-I
INTENSIFIER
PVA-00L3
3-WAY VALVE

6
TYPICAL DOUBLE ACTING SET-UP
(4-WAY VALVE REQUIRED)
(SHOWN BELOW)
PVA 1122
CONTROL VALVE W/ 3VE3 HOS-
3VE3
10,000 PSI HOSE SET
3VE3
10,000 PSI HOSE
The REL-10-I-S/DA is the perfect 10,000 psi
power source, providing all the benefi ts of a
double acting tool system, while complementing
existing single acting tool inventories.
Power, function, and simplicity have been
combined into this unique all in one hydraulic
power system.
This system combines the power of a high
pressure intensifi er with the simplicity of a fi xed
position three way control valve.
When using the single acting connection:
REL-10-I-SA/D provides quick advance and
retract for high pressure (10,000 psi) single acting
spring return tools, without the need for additional
H/P hoses, couplers or an in-line control valve.
When using the double acting connection:
REL-10-I-SA/D provides quick advance and
retract for high pressure (10,000 psi) double
acting tools, combined with the versatility and
effi ciency of a four way control valve.
REL-10-I-S/DA
TYPICAL SINGLE ACTING SET-UP
(SHOWN ON THE RIGHT)
REL-10-I-S/DA
REL-10-I-S/DA
REL-60SA
S/A CRIMPING HEAD
REL-60DA
D/A CRIMPING HEAD
SPECIFICATIONS
HYDRAULIC SYSTEM ................ Open or Closed Center
MOTOR .........................................................Gear Driven
OPERATING PRESSURE ....................... 1,400-2,000 psi
FLOW RANGE .................................................... 4-7 gpm
OPTIMUM OPERATING PRESSURE ..1,800 psi @ 6 gpm
OUTPUT - FAST ADVANCE MODE ............. 305 in. 3/min
OUTPUT - HIGH PRESSURE MODE ............ 30 in. 3/min
RELIEF VALVE SETTING ................... 4,000 - 10,000 psi
S/A HIGH PRESSURE PORT ........................ 3/8 in. NPT
D/A HIGH PRESSURE PORT ........................ 1/4 in. NPT
LOW PRESSURE INLET PORT..................... 3/8 in. NPT
LOW PRESSURE RETURN PORT ................ 3/8 in. NPT
SPECIAL FEATURES
HIGH PRESSURE COUPLERS ..........................Included
ADJUSTABLE MOUNTING BRACKETS .........Included
UL-BCA - MOUNTING BUCKET ......................Optional
RELIABLE EQUIPMENT COMBINES FORCE & FUNCTION

7
SPECIFICATIONS - HYD. POWER SOURCE
200 PSI back pressure is the maximum agreed standard for the Hydraulic Tool Manufacturers Association (HTMA).
1. Maximum fluid temperature must not exceed 140OF (60OC) at the maximum expected
ambient temperature. A sufficient oil cooling capacity is needed to limit the fluid temperature.
2. Maximum fl ow must not exceed 8 GPM. Install a fl ow meter in the return line to test the rate of fl ow
in the system before working the tool.
3. Pressure relief valve must not exceed 2,200 PSI. The pressure relief valve must be located in the
supply circuit between the pump and the intensifi er to limit excessive pressure to the tool.
Any hydraulic power source used with this unit must meet the requirements above.
ADJUSTABLE
MOUNTING BASE
DOUBLE ACTING
HIGH PRESSURE CONNECTIONS
1/4” N.P.T.
RETURN PORT
FOR DOUBLE ACTING
TOOL CONNECTION
LOW PRESSURE PORTS
(TO POWER SUPPLY)
PVA-00L3
SINGLE-ACTING CONTROL VALVE
REL-10-I
INTENSIFIER
REL-10-I-S/DA
SINGLE / DOUBLE ACTING
HIGH PRESSURE CONTROL SYSTEM
(4-WAY CONTROL VALVE REQUIRED
FOR D/A OPERATION)
3/8” N.P.T.
SINGLE ACTING
HIGH PRESSURE
CONNECTION
1/4” N.P.T.
PRESSURE PORT
FOR DOUBLE ACTING
TOOL CONNECTION
The REL-10-I intensifi er will increase line
pressure to a maximum of 10,000 psi and
is fully compatible with all high pressure
hydraulic equipment.
The PVA-00L3 single-acting control
valve, provides 3-way control (Advance,
Neutral, and Retract) direct from the high
pressure source.
Together this intensifier/valve package
allows return oil to bypass the intensifi er
and return directly to the tank (return) line,
increasing tool speed and performance.
TANK
3/8” M.N.P.T.
PRESSURE
3/8” F.N.P.T.

8
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
WARNING
Protective
Gloves
Always wear protective gloves
Failure to do so can result in serious
personal injury.
WARNING
Hydraulic oil may cause irritation.
Use care to prevent contact with skin.
In case of accidental contact, wash
affected area immediately
Skin
Irritation

9
WARNING
Safety
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 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

10
Safe Handling
HYDRAULIC FLUID MAY CAUSE SKIN IRRITATION.
Prevent hydraulic fluid from making contact with skin.
IN THE EVENT OF SKIN CONTACT immediately wash thoroughly.
Failure to observe this warning could result in injury.
CAUTION
Electrical Shock Hazard
Use only certified nonconductive hoses and fittings. 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
CAUTION
General Safety
Ensure that all fellow employees and bystanders are clear
and protected from possible injury caused by this tool or the
operations being performed. Persons in close proximity could
be injured and property damaged if the tool were to malfunction.
This tool should always be used within the limits and purposes
stated by the product manufacturer. Abuse or usage beyond the
manufacturers’ intended purposes could cause damage to the
tool and severe injury to the operator.
Burn Hazard
Do Not connect or disconnect tool, hoses or fittings while power
source is running or while hydraulic fluid is hot. Hot hydraulic
fluid may cause serious burns.
Failure to observe this warning could result in serious injury.
WARNING
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.

11
PRE-OPERATION OF TOOL
Before attempting to run or use the REL-10-I, REL-10-I-SA or connected tools, check
all connections, including hoses, and couplings. (See WARNINGS on pages 4-7)
Wear all safety items required, and make sure that the working area is clear of obstructions
and non-essential personnel.
DO NOT connect hoses or fittings to pump before reading all of the
instructions in this section.
Ensure power source is OFF, hydraulic flow is turned OFF.
Failure to comply with this warning can result in severe injury or death.
WARNING
HYDRAULIC FLUIDS
All hydraulic fluids that meet these listed specifications or the listed HTMA specifications may
be used for this tool.
S. U. S.
@ 100OF (38OC) ......................................................................... 140 TO 225
@ 210OF (99OC) ....................................................................... 40 minimum
FLASH POINT ...................................................... 340OF min. (170O C min.)
POUR POINT ......................................................... -30OF min. (-34OC min.)
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
If you have any questions regarding the information found in this manual please
contact the supervising authority, or
RELIABLE EQUIPMENT before continuing.
Phone: [phone] Toll Free: 800-966-3530 Fax: [phone]
NOTICE

12
UNIT/HOSE CONNECTIONS
ALWAYS TURN OFF hydraulic source and move valve handle to
RETRACT before connecting or disconnecting any components.
ALWAYS DEPRESSURIZE hydraulic system, before slowly
connecting/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. Tool damage or severe injury could result.
WARNING
HOSE INSTALLATION
1. ENSURE POWER SOURCE IS OFF AND OIL HAS COOLED,
2. ENSURE HYDRAULIC FLOW IS TURNED OFF.
3. ALWAYS ENSURE CONNECTORS ARE CLEAN.
4. CONNECT HOSES TO HYDRAULIC SUPPLY.
5. ENSURE THAT THE VALVE IS IN THE RETRACT POSITION.
6. CONNECT THE REL-10-I-SA INTENSIFIER.
7. ENSURE THAT THE VALVE IS IN THE RETRACT POSITION.
8. CONNECT THE HOSE TO THE PRESSURE PORT ON THE
REL-10-I-SA, THEN CONNECT TO THE PORT ON THE TOOL.
CAUTION
DISCONNECTING HOSES
Turn OFF hydraulic source, ensure valve handle is in the
RETRACT position and oil has cooled before disconnecting the
hydraulic source, tool, or hoses.
Disconnect hose from the REL-10-I-SA, before disconnecting the tool.
Disconnect the pressure hose from the pressure “P” port on the
hydraulic source, then disconnect the hose from the pressure port
on the REL-10-I-SA.
Disconnect the return hose from the return “T” port on the REL-10-I-SA,
then disconnect the hose from the return (tank) port on the source.
Install dust caps on all connectors to prevent dirt and contaminents
from entering the hydraulic system.
CAUTION
WARNING: Failure to comply with these warnings may result in severe bodily injury.

13
USE ALL APPROPRIATE AND APPLICABLE
PERSONAL SAFETY PROCEDURES AND EQUIPMENT
AS REQUIRED BY THE OPERATING COMPANY.
Inspect, set-up and connect the tool as described on the
previous pages.
WARNING: DO NOT connect or disconnect the tool,
hoses, or fittings while the tool is running, hot, or under
pressure. Serious injury or burns could result.
Replace all parts that show signs of wear or damage.
A damaged or improperly assembled tool may injure operator
and/or nearby personnel.
Set up desired operation. (ie. crimp, cut, or spearing).
Review and understand all operation and safety guidelines
relating to the operation to be performed.
Ensure that valve is in the RETRACT position before
initiating hydraulic power souce.
Activate the REL-10-I-SA by moving valve handle to the
ADVANCE position. Thetooloperation willbeginimmediately.
NOTE: Moving the valve handle to the HOLD (center)
position will stop the tool action allowing for confi rmation
and repositioning as needed.
When relief valve popping occurs desired pressure has been
achieved and operation should be complete.
Repeat as necessary.
NOTE: Holding valve handle in the ADVANCE position
after relief valve has popped will cause unnecessary wear
on relief valve and pump assembly.
Move valve to RETRACT and allow tool cutting blades,
crimping jaws or ram to return fully.
Valve should be in the RETRACT position when not in use.
REL-10-I-SA OPERATION
LOW PRESSURE PORTS
(TO POWER SUPPLY)
HIGH PRESSURE
SINGLE ACTING PORT
VALVE HANDLE
REL-10-I
INTENSIFIER
PVA-00L3
3-WAY VALVE
REL-10-I-SA
INTENSIFIER/VALVE
Move valve handle to desired
action ADV (advance) or
RET (retract)
return to HOLD upon com-
pletion of operation
PVA-00L3
3-WAY VALVE
NOTICE
If you have any questions regarding the information found in this manual please
contact the supervising autority, or RELIABLE EQUIPMENT before continuing.
Phone: [phone] Toll Free: 800-966-3530 Fax: [phone]

14
USE ALL APPROPRIATE AND APPLICABLE PERSONAL
SAFETY PROCEDURES AND EQUIPMENT AS REQUIRED
BY THE OPERATING COMPANY.
Inspect, set-up and connect the tool as described on the
previous pages.
WARNING: DO NOT connect or disconnect the tool,
hoses, or fittings while the tool is running, hot, or under
pressure. Serious injury or burns could result.
Replace all parts that show signs of wear or damage.
A damaged or improperly assembled tool may injure operator
and/or nearby personnel.
Set up desired operation. (ie. crimp, cut, or spearing).
Review and understand all operation and safety guidelines
relating to the operation to be performed.
Ensure that valve is in the RETRACT position before
initiating hydraulic power souce.
Activate the REL-10-I-SA by moving valve handle to the LEFT
ADVANCE position. The tool operation will begin immediately.
NOTE: Moving the valve handle to the HOLD (center)
position will stop the tool action allowing for confi rmation
and repositioning as needed.
When relief valve popping occurs desired pressure has been
achieved and operation should be complete.
Repeat as necessary.
NOTE: Holding valve handle in the ADVANCE position
after relief valve has popped will cause unnecessary wear
on relief valve and pump assembly.
Move valve to RIGHT/RETRACT and allow tool cutting
blades, crimping jaws or ram to return fully.
Valve should be in the RETRACT position when not in use.
REL-10-I-SAD S/A OPERATION
NOTICE
LOW PRESSURE PORTS
(TO POWER SUPPLY)
H/P SINGLE ACTING
PRESSURE PORT
VALVE HANDLE
REL-10-I
INTENSIFIER
PVA-00L3
3-WAY VALVE
PVA-00L3
3-WAY VALVE
H/P DOUBLE ACTING
PRESSURE PORT
DOUBLE ACTING
RETURN PORT
Move valve handle
to desired action
LEFT/ADV (advance)
or RIGHT/RET (retract)
return upon completion
of operation.
If you have any questions regarding the information found in this manual please
contact the supervising autority, or RELIABLE EQUIPMENT before continuing.
Phone: [phone] Toll Free: 800-966-3530 Fax: [phone]

15
USE ALL APPROPRIATE AND APPLICABLE PERSONAL
SAFETY PROCEDURES AND EQUIPMENT AS REQUIRED
BY THE OPERATING COMPANY.
Inspect, set-up and connect the tool as described on the
previous pages. NOTE: AN IN LINE FOUR WAY CONTROL
VALVE IS REQUIRED FOR DOUBLE ACTING OPERATION.
WARNING: DO NOT connect or disconnect the tool, hoses, or
fittings while the tool is running, hot, or under pressure.
Tool damage, serious injury or burns may result.
Replace all parts that show signs of wear or damage.
A damaged or improperly assembled tool may injure operator
and/or nearby personnel.
Set up desired operation. (ie. crimp, cut, or spearing).
Review and understand all operation and safety guidelines relating
to the operation to be performed.
Ensure that valve is in the RETRACT position before initiating
hydraulic power souce.
Activate the REL-10-I-SA/D by moving valve handle to the LEFT/
ADVANCE position.
Operate in-line control valve to activate double acting tool and
begin cutting or crimping procedure.
When relief valve popping occurs desired pressure has been
achieved and operation should be complete.
NOTE: Holding control valve in the ADVANCE position after relief
valve has popped will cause unnecessary wear on relief valve
and pump assembly.
Use the in-line control valve to open or retract tool jaw/blades.
Repeat as necessary.
Move valve handle to RIGHT/RETRACT to stop pressure.
Valve should be in RIGHT/RETRACT position when not in use.
WARNING: ALWAYS ensure valve handle is in the retract
position and hydraulic source is turned off before you connect
or disconnect the tool, hoses, or fittings while the tool is running,
hot, or under pressure.
Serious property damage, injury, or burns may result.
REL-10-I-SAD D/A OPERATION
LOW PRESSURE PORTS
(TO POWER SUPPLY)
H/P SINGLE ACTING
PRESSURE PORT
VALVE HANDLE
REL-10-I
INTENSIFIER
PVA-00L3
3-WAY VALVE
Move valve handle
to desired action
LEFT/ADV (advance)
or RIGHT/RET (retract)
return upon completion
of operation.
PVA-00L3
3-WAY VALVE
H/P DOUBLE ACTING
PRESSURE PORT
DOUBLE ACTING
RETURN PORT
LEFT RIGHT
NOTICE
If you have any questions regarding the information found in this manual please
contact the supervising autority, or RELIABLE EQUIPMENT before continuing.
Phone: [phone] Toll Free: 800-966-3530 Fax: [phone]

16
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 unqualifi ed 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
IMPORTANT: The greatest cause of hydraulic pump/valve failure is dirt.
Prevent the introduction of foreign matter into the unit via hydraulic fluid,
dirty connections or accumulation of sediment.
SCHEDULED MAINTENANCE
The life, reliability, and safety of the tool is dependent on proper maintenance.
DAILY MAINTENANCE
Clean all surfaces including, hand control, fittings, hoses and housing.
Inspect tool for wear and damage. Worn or damaged parts can cause malfunction.
Inspect for cracked hoses and leaking fittings.
Check fluid level of the power source reservoir frequently.
All the above items must be replaced with new parts if signs of wear are evident.
FLUID CONTAMINATION: Cover the ends of fittings with a dust cap when disconnected.
This will help keep the fluid from contamination.
MONTHLY MAINTENANCE: Inspect per Appendix A, SAE Standard J1273, 5/86 for
hose or fitting damage such as wear, cracks or leakage; replace the necessary parts.
NOTE: Keep Label Set clean and legible. Replace decals when necessary.
Complete disassembly is not recommended.

17
Before disassembly, disconnect hoses as described in this
manual. Any residual pressure within the unit can and will spray
at high velocity, injuring the person doing the disassembly. Hot
or pressurized hydraulic fluid will cause serious injury or death.
Complete disassembly is not recommended. Return the unit
to an authorized dealer for total disassembly and/or repair.
WARNING
READ BEFORE DISASSEMBLY
WARNING
Safety
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.
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 parts.
Use only factory specified parts when repairing and/or replacing.
Severe damage to the tool can occur with non-specified 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.
The unique plumbing required to integrate the REL-10-I with the PVA-00L3 3-way valve is
custom fi tted for each unit, and cannot be purchased for non-factory repairs at this time.
If any unit requires repair or replacement of these parts, please return to RELIABLE for
factory authorized service.
If you have any questions regarding the information found in this manual
please contact the supervising authority or RELIABLE EQUIPMENT before
continuing.

18
REL-10-I
INTENSIFIER
DRAWING #1
REL-10-I
INTENSIFIER
DRAWING #2
Reference
Parts List on
Next Page
Reference
Parts List on
Next Page

19
REF. PART QTY. DESCRIPTION
* 3 12732 1 BUSHING (PRESSURE)
6 12736 6 SHAFT BEARING
7 12737 1 CAM BEARING ASSEMBLY
** 9 12739 3 O-RING HOLE SEAL
10 12740 2 SPRING (PINTLE)
** 11 12742 2 O-RING SHAFT SEAL
18 12769 4 THRUST WASHER
21 12772 1 INSERT REAR
23 12774 2 BEARING (THRUST)
** 27 12778 1 BACK-UP RING
** 28 12779 1 O-RING BUSHING
29 12780 1 VALVE ASSEMBLY
32 12783 2 BALL (3/16“)
34 12786 4 SCREW
39 12791 5 1/16 NPT PLUG
40 12792 1 1/4 NPT PLUG
42 12794 1 1/2 NPT PLUG
** 45 12741 1 O-RING REAR SEAL
59 16101 1 BLOCK ASSEMBLY, HIGH PRESSURE
60 16102 1 PISTON & BUSHING ASSEMBLY
* 61 16103 1 VALVE SEAT, HIGH PRESSURE
62 16104 1 SUPPLY CHECK VALVE BODY
63 16105 1 SUPPLY CHECK VALVE SEAT
* 67 * 4 O-RING
69 K3197 1 PISTON & BUSHING ASSEMBLY
* 70 12254 1 COPPER WASHER
REF. PART QTY. DESCRIPTION
2 12731 1 CAM SHAFT ASSEMBLY
6 12736 6 SHAFT BEARING
** 8 12738 2 O-RING FACE SEAL
** 9 12739 3 O-RING HOLE SEAL
13 12745 2 PUMP GEAR
16 12767 1 PUMP BLOCK
20 12771 1 SHAFT (IDLER, PUMP)
25 12776 2 PIN (DRIVE)
40 12792 3 1/4 NPT PLUG
43 12795 2 PINS (DRIVE)
44 12796 4 DOWELS
47 12735 1 REV. CHECK ADAPTER
48 12744 1 3/8 BALL
49 12743 1 BALL SEAT
** 50 12748 1 O-RING
* TO BE SOLD AS A MATCH SET
** SUPPLIED IN SEAL KIT K3195 SAPRTLST 12/20/96
DRAWING #1 PARTS LIST (BEGINNING W/ S/N # 3000)
DRAWING #2 PARTS LIST

20
REL-10-I
INTENSIFIER
DRAWING #3
REF. PART QTY. DESCRIPTION
6 12736 6 SHAFT BEARING
** 8 12738 2 O-RING FACE SEAL
14 12746 2 RETURN GEAR (please advise serial # when ordering)
17 12768 1 PUMP GEAR (RETURN BLOCK)
22 12773 1 SHAFT (IDLER, RETURN)
30 12781 2 MOUNT
36 12788 4 SCREW (SCFH)
37 12789 6 SREW (SHCS)
38 12790 6 LOCKWASHER
43 12795 4 PINS (DRIVE)
44 12796 4 DOWELS
** SUPPLIED IN SEAL KIT K3195 SAPRTLST 12/20/96
DRAWING #3 PARTS LIST
Reference
Parts List Be-
low
If you have any questions regarding the information found in this manual please
contact the supervising autority, or RELIABLE EQUIPMENT before continuing.
Phone: [phone] Toll Free: 800-966-3530 Fax: [phone]