Reliable Equipment REL-430 Manual

1
DISTRIBUTED BDISTRIBUTED B
DISTRIBUTED BDISTRIBUTED B
DISTRIBUTED BYY
YY
Y
OPERAOPERA
OPERAOPERA
OPERATORS’ GUIDETORS’ GUIDE
TORS’ GUIDETORS’ GUIDE
TORS’ GUIDE
MAN. HYD. CRIMPING Manual 09-14
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-430, REL-510, & REL-510K
HAND OPERATED HYDRAULIC CRIMPING TOOLS
REL-430 REL-510 REL-510K

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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.
DISTRIBUTED BDISTRIBUTED B
DISTRIBUTED BDISTRIBUTED B
DISTRIBUTED BYY
YY
Y

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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 .............................................................2
TABLE OF CONTENTS ............................................................................3
REGISTRATION .......................................................................................3
TOOL SPECIFICATIONS
REL-430 ...............................................................................................4
REL-510 ...............................................................................................5
REL-510K.............................................................................................6
SAFETY INFORMATION AND WARNINGS ..................................... 7-8
DAILY MAINTENANCE ............................................................................9
OPERATING INSTRUCTIONS ...............................................................9
MAN. HYD. CRIMPING HANDLE PARTS LIST ..............................10-11
FIXED HANDLE PART DRAWING #1 .......................................... 12
MOVABLE HANDLE PART DRAWING #2................................... 13
NOTE: FIXED HANDLE DWG #1 AND MOVABLE HANDLE DWG #2
PART #S WILL REMAIN CONSTANT FOR ALL MODELS, REFER
TO HANDLE PARTS LIST ON PAGES 10 AND 11 FOR THESE ITEMS.
REL-510
REL-510 HEAD DRAWING #3 ...................................................... 14
REL-430 HEAD PARTS LIST ......................................................... 15
REL-430
REL-430 HEAD DRAWING #4 ...................................................... 16
REL-430 HEAD PARTS LIST ......................................................... 17
REL-510K
REL-510K HEAD DRAWING #5.................................................... 18
REL-510K HEAD PARTS LIST....................................................... 19
LABELS................................................................................................... 20
MAINTENANCE RECORDS................................................................. 22
CONTACT INFORMATION................................................................... 22

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Designed to crimp splices to 600 MCM and lugs to
750 MCM. The REL-430 Accepts standard Reliable
R12 (12 ton) “U” style dies as well as many dies
from Alcoa, Burndy, Blackburn, Thomas & Betts,
and Huskie. The 1-3/16" jaw opening allows use
on larger cable diameters and connectors than
standard 1" opening tools. The 180O swivel head
permits use in confined areas. Replaceable drop
out by-pass cartridge facilitates shop repairs.
Two-stage pumping piston for rapid advance,
and twist handle release. Magnetic oil reservoir
plug traps metal contaminants.
Connector Range:Connector Range:
Connector Range:Connector Range:
Connector Range:
Lugs Up to 750 MCM
Splices Up to 600 MCM
FEATURES:
Crimping Head rotates 180O
´Replaceable drop-out bypass cartridge
´Accepts all existing R12 “U” Style dies
´Two stage pumping piston
´Twist handle release
´Carrying case included
Weight: 13.5 lbs., Length: 24 inches
REL-430 MANUAL HYDRAULIC 12 TON CRIMPING TOOL
Reliable Equipment’s line of
manual hydraulic compression
tools offer a unique bypass
system, featuring an adjustable,
replaceable bypass cartridge.
This unit can be easily replaced
or externally calibrated without
dismantling the tool.
This tool can be recalibrated in
the field, using a hex wrench to
adjust desired pressure, without
removing the tool from service.
Bypass Cartridge
REL-430
REL-430

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Designed to crimp splices to 750 MCM and lugs
to 750 MCM Al & Cu. The REL-510 Accepts
standard Reliable R12 (12 ton) “U” style dies as
well as many dies from Alcoa, Burndy, Blackburn,
Thomas & Betts, and Huskie. The 1-1/2" jaw
opening allows use on larger cable diameters and
connectors than standard 1" opening tools. The
180O swivel head permits use in confined areas.
Replaceable drop out by-pass cartridge facilitates
shop repairs. Two-stage pumping piston for rapid
advance, and twist handle release. Magnetic oil
reservoir plug traps metal contaminants.
CONNECTCONNECT
CONNECTCONNECT
CONNECTOR RANGE:OR RANGE:
OR RANGE:OR RANGE:
OR RANGE:
Lugs Up to 750 MCM
Splices Up to 750 MCM
FEATURES:
Crimping Head rotates 180O
´Replaceable drop-out bypass cartridge
´Accepts all existing R12 “U” Style dies
´Two stage pumping piston
´Twist handle release
´Carrying case included
Weight: 14.5 lbs., Length: 25 inches
REL-510 MANUAL HYDRAULIC 12 TON CRIMPING TOOL
Reliable Equipment’s line of
manual hydraulic compression
tools offer a unique bypass
system, featuring an adjustable,
replaceable bypass cartridge.
This unit can be easily replaced
or externally calibrated without
dismantling the tool.
This tool can be recalibrated in
the field, using a hex wrench to
adjust desired pressure, without
removing the tool from service.
Bypass Cartridge
REL-510
REL-510

6
Designed to crimp splices to 477ACSR and lugs to
1033 MCM. The REL-510K accepts standard
Kearney style dies. The 1-1/2 inch jaw opening
allows use on larger cable diameters and
connectors than standard 1" opening tools.
Additional features include: 180O swivel head which
permits use in confined areas. The replaceable drop
out by-pass cartridge facilitates shop repairs.
Two-stage pumping piston for rapid advance,
and twist handle release. Magnetic oil reservoir
plug traps metal contaminants.
Connector Range:Connector Range:
Connector Range:Connector Range:
Connector Range:
Lugs Up to 477 ACSR
Splices Up to 1033 MCM
FEATURES:
Crimping Head rotates 180O
´Replaceable drop-out bypass cartridge
´Accepts all existing R12 “U” Style dies
´Two stage pumping piston
´Twist handle release
´Carrying case included
Weight: 17 lbs., Length: 26 inches
REL-510K MANUALHYDRAULIC12TONCRIMPINGTOOL
Reliable Equipment’s line of
manual hydraulic compression
tools offer a unique bypass
system, featuring an adjustable,
replaceable bypass cartridge.
This unit can be easily replaced
or externally calibrated without
dismantling the tool.
This tool can be recalibrated in
the field, using a hex wrench to
adjust desired pressure, without
removing the tool from service.
Bypass Cartridge
REL-510K
REL-510K

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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
WARNING
Always wear foot protection.
Failure to do so can result in serious
personal injury.
Dust Mask
WARNING
Always wear a dust mask. Failure to
observe this warning may result
in serious health issues and/or
breathing difficulty.
WARNING
Protective
Gloves
Always wear protective gloves
Failure to do so can result in serious
personal injury.

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GENERAL SAFETYGENERAL SAFETY
GENERAL SAFETYGENERAL SAFETY
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.
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 JAWS AT TOOL HEAD.
ALL BODY PARTS SHOULD BE OUTSIDE DANGER ZONE PRIOR TO CRIMPING.
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 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
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

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DAILY MAINTENANCE
The life, reliability, and safety of the tool is dependent on proper maintenance.
Clean all surfaces including head, die seat, ram, 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.
Keep Label Set clean and legible. Replace decals when necessary.
OPERAOPERA
OPERAOPERA
OPERATIONTION
TIONTION
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 7 and 8 )
Before crimping, ensure that crimp is within the capacity listed for the tool.
Ensure that you are using the proper die, as recommended by the connector manufacturer.
Insert proper die into die seat using die buttons. NEVER OPERATE WITHOUT DIES.
Place tool over connector.
Advance ram to connector with fast advance feature on handle.
Align jaw as necessary to ensure proper crimp.
NOTE: Jaw may be released as needed at any point in the crimp cycle.
Continue pumping until relief valve “pops” off. Action will become very easy.
Crimp is complete.
To release ram from connector, open pump handle completely.
Rotate pump handle (movable) 45O & hold while closing completely.
This will release the ram & retract from connector.
Repeat steps above as necessary.
Manufacturer recommends regular testing for proper pressure and operation.
Test at least every 6 months, test more often under heavy usage.
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

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MAN. HYD. CRIMPING HANDLE PARTS LIST
ITEM QTY PART NO DESCRIPTION DRAWING #
1 1 R19101 BODY, MACHINED 2
7 1 R18007 RETURN SPRING 2
8 1 R18008 CAP, SPRING 2
9 1 R18009 SNAP RING, CAP STOP 2
10 1 R19010 REAR STOP 1
12 2 R18012 HARD BALL, 7/32 DIA. 1, 2
13 2 * R18013 O’RING 1, 2
14 2 * R18014 BU RING 1, 2
15 1 R18015 RELEASE PLUNGER 2
16 1 R18016 SPRING, RELEASE 1
17 1 R18017 BRASS NUT 2
18 1 R18018 SIDE PLUG 2
19 1 R18019 PINTLE, SIDE PLUG 2
20 1 R18020 CHECK CAP 1
21 1 R18021 BALL, 3/16, FEED CHK. 1
22 1 R18022 FILTER BODY 1
23 1 R18023 SCREEN, BRASS 1
24 1 R18024 FINGER CLIP 1
25 1 R18025 MOUNT, BODY HANDLE 1
26 1 R18026 RESERVOIR PLUG ASSY, R410-55 1
27 1 R18027 MAGNET, ASSY R410-55 1
28 1 R18028 HANDLE, FIBERGLASS BODY, 430-10HT 1
29 1 R18029 PUMP ARM, FIBERGLASS, 410-30 2
30 1 R18030 SHOULDER HOUSING 2
31 1 R18031 POINTER 2
32 1 R18032 RELEASE FINGER 2
33 4 R18033 BRONZE BUSHINGS 2
34 1 R18034 KNUCKLE 2
35 1 R18035 FAST ADV. PLUG 1
36 1 R18036 SET SCREW, 6-32 X 3/16 2
37 1 R18037 3/32 BALL 2
38 1 R18038 LOWER CHK. SPRG. 1
39 2 R18039 UPPER CHK SPRG. 1
40 1 R28540 PISTON INJECTOR 2