Reliable Equipment REL-LP-O Manual

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DISTRIBUTED BY
OPERATORS’ GUIDE
REL-LP 6 Ton Series Manual 06-17
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-LP SERIES
6 TON LOW PRESSURE HYDRAULIC CRIMPING TOOL
RELIABLE EQUIPMENT & SERVICE CO., INC.
301 Ivyland Road • Warminster, PA 18974 • USA
Phone: [phone] • Fax: [phone]
MODEL: __________________________________
MAX. PRESSURE: _________________________
SERIAL NO.: ______________________________
YEAR: ___________________________________
Accepts: Reliable R6 & “W” Type Dies 6 Ton Dies

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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 BY

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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
REGISTRATION ..................................................................................... 2
TABLE OF CONTENTS ......................................................................... 3
TOOL SPECIFICATIONS
REL-LP - 6 ton Series.............................................................. 4
SAFETY INFORMATION AND WARNINGS ........................................ 5-9
OPERATING INSTRUCTIONS ............................................................. 10
DIE INSTALLATION ............................................................................. 11
DISCONNECTING HOSES .................................................................. 12
MAINTENANCE, INSPECTION & TESTING........................................ 13
GENERAL MAINTENANCE.................................................................. 14
JAW STYLE DIAGRAM ....................................................................... 15
PARROT STYLE JAW ASSEMBLY
DRAWING............................................................................... 16
PARTS LIST............................................................................ 17
LOW PRESSURE INTENSIFIER & HANDLE ASSY.
DRAWING............................................................................... 18
PARTS LIST............................................................................ 19
LOW PRESSURE HANDLE ASSEMBLY.............................................. 20
NOTES ............................................................................................... 21
MAINTENANCE RECORDS................................................................. 22
CONTACT INFORMATION .................................................................. 22
If you have any questions regarding the information
found in this manual please contact RELIABLE EQUIPMENT
at 800-966-3530 or FAX [phone].

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REL-LP-O, BG, KO, K58, or SN
6 TON, LOW PRESSURE,
HYDRAULIC CRIMPING TOOL
Operate from any 1,500-2,500 psi hydraulic
power source. NO H/P intensifier needed.
Smaller than many equivalent 6 ton low
pressure crimping tools currently available.
Crimp up to 4/O Copper or Aluminum.
Operate on Open- or Closed- Center systems.
Crimping head swivels 180O on handle.
D3 seat accepts R6 and “W” style dies.
REL-LP-K_ models accept Kearney style dies.
301 Ivyland Road, Warminster, PA 18974
Phone: [phone] • Fax: [phone]
Visit us on the web at www.Reliable-Equip.com
REL-LP-O, BG, KO, K58 or SN
6 TON LOW PRESSURE HYDRAULIC CRIMPING TOOL
SPECIFICATIONS
System Open/Closed Center
Force 12,000 lb.
Pressure 1,500-2,500 psi
Flow 3-9 gpm
Capacity 4/O Copper and Aluminum
* Dies not included.
Length: 19 in.
Weight: 10 lbs. Dry
Fixed O or BG Nose
with D3 Die Seat
Accepts R6 & W
Style Dies
Fixed O or 5/8 Nose
Accepts Kearney Dies
D3 Die Seat
Accepts R6 & W
Style Dies

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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
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
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
WARNING
WARNING
WARNING

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WARNING
CRIMP DANGER
This hydraulic crimping tool can crush 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 injury
SERIOUS BURN HAZARD
HOT SURFACES MAY CAUSE SERIOUS BURNS.
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
FIRE HAZARD
An incomplete crimp may pose a fire hazard.
Always use the appropriate connector, die set, and compression
tool, as required by the intended application.
When the pressure relief valve sounds, the crimp tool has
reached maximum pressure, and the crimp is complete.
Compression tool should be tested on a regular schedule to
ensure pressure relief valve activates at the proper pressure.
Failure to observe this warning could result in serious injury.
WARNING
TOOL HAZARD
DO NOT OPERATE TOOL WITHOUT DIES.
DO NOT EXCEED THE MAXIMUM HYDRAULIC FLOW, RELIEF
PRESSURE, OR BACK PRESSURE.
Failure to observe warnings could result in tool damage or injury.
WARNING

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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 personal 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 certifi ed
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 & fi ttings 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
fi ttings 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 signs of wear, damage,
or leakage are evident. Leakage is a sign of deterioration in
component parts. Worn or leaking parts must be repaired
or replaced, or tool damage and/or severe injury could result.
WARNING
HOSE INSTALLATION
ALWAYS ENSURE CONNECTORS ARE CLEAN
Care must be taken to assure the correct connection of the hoses to
the pressure and return (tank) ports.
Connect the return hose to the return (tank) port on the power source,
then to the return port on the tool.
Connect the pressure hose to the pressure port on the tool, then to
the “P” pressure port on the power source.
Operation with hydraulic flow reversed can cause malfunction.
Failure to comply with warnings may result in severe injury or death.
CAUTION

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GENERAL SAFETY
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 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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OPERATION
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
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 6 through 10 )
Select Open-Center or Closed-Center
1. The person operating the tool must know the type of hydraulic system on which
the tool is being used.
2. On the right side of the body, just in front of the OC/CC Knob is an engraved line.
Newer versions of the REL-425 will have an arrow cast into the body. For open-center
systems, the “O” on the back of the Knob should be aligned with the marking on the
side, and for closed-center systems the “C” is aligned.
3. While using the tool, the operator should check the OC/CC alignment frequently in
the event it becomes inadvertently disoriented.
Before crimping, ensure that crimp is within the capacity listed for the tool.
Refer to connector manufacturer’s instructions for cable preparation and crimping procedure.
Ensure that you are using the proper die, as recommended by the connector manufacturer.
Insert proper die into die seat. Refer to appropriate DIE INSTALLATION on next page.
Place tool over connector. Center connector between the dies.
Align jaw as necessary to ensure proper crimp.
Press the trigger to advance the dies.
Compress trigger partially for slow advance.
Compress trigger completely for fast advance.
NOTE: Jaw may be released as needed at any point in the crimp cycle.
Continue cycle until pressure has been achieved. Crimp is complete.
Ram will retract automatically when trigger is released.
Repeat steps above as specifi ed by connector manufacturer.
NOTE: To reduce heat and wear on tool components, stop the power source,
when the tool is not in use.
Manufacturer recommends regular testing for proper pressure and operation.
Test at least every 6 months, test more often under heavy usage.
Select Open-Center or Closed-Center (No tools Required)
1. The person operating the tool must know the type of hydraulic system on which
the tool is being used.
2. On the top of the handle body, just in front of the OC/CC knob, there is an arrow
cast into the body. For open-center systems, the “O” on the Knob should be
aligned with the marking, and for closed-center systems the “C” is aligned.
NOTE: Trigger must be fully compressed before turning selector knob.
3. While using the tool, the operator should check the OC/CC alignment frequently
in the event it becomes inadvertently disoriented.