Textron Greenlee LP6 GMA Series User manual

INSTRUCTION MANUAL
52062769 REV 1 © 2013 Greenlee Textron Inc. 1/13
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
LP6
Hydraulic Crimping Tool
Serial Codes GMA, GMB, GMD, and GME

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The LP6 Hydraulic Crimping Tool is a hand-held crimp-
ing tool with removable crimping jaws that is intended to
crimp connectors onto electrical cable.
This tool is factory set for operation on an open-center
or closed-center hydraulic system.
Safety
Safety is essential in the use and maintenance of
Greenlee Utility tools and equipment. This manual and
any markings on the tool provide information for avoid-
ing hazards and unsafe practices related to the use of
this tool. Observe all of the safety information provided.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee Utility tools:
LP6-01 Serial Code GMB
LP6-02 Serial Code GMA
LP6-03 Serial Code GMD
LP6-04 Serial Code GME
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge at www.greenlee.com.
Other Publications
Tool Owners/Users
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 99930323
All specications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
KEEP THIS MANUAL
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
Other Publications.......................................................... 2
Important Safety Information ..................................... 3–5
Identication................................................................... 6
Specications................................................................. 7
Hoses and Fittings ......................................................... 8
Hose Connections.......................................................... 8
Typical Setup.................................................................. 8
Operation.................................................................. 9–10
Maintenance................................................................. 11
Periodic Pressure Relief Valve Check........................... 11
Troubleshooting............................................................ 12
Illustrations and Parts Lists .................................... 13–16

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning
could result in severe injury or death.
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use only certied
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning
could result in severe injury or death.
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punc-
tures skin, causing serious injury,
gangrene, or death. If you are
injured by escaping oil, seek medical
attention immediately.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Wear hearing protection when using
this tool.
Long-term exposure to high noise
levels could result in hearing
damage.

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
The hydraulic cylinder may be hot
during and after operation. Hot sur-
faces can cause serious burns.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning
could result in severe injury or death.
An incomplete crimp can cause a re.
• Use proper die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
• The relief valve sounds to indicate a completed
crimp. If you do not hear the sound of the relief
valve, the crimp is not complete.
Failure to observe this warning could result in severe
injury or death.
Do not exceed the following hydraulic power source
maximums:
• Hydraulic ow: 34.1 l/min (9 gpm).
• Pressure relief setting: 172 bar (2500 psi).
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.
Do not disconnect tool, hoses, or ttings while the
power source is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Do not reverse hydraulic ow. Operation with
hydraulic ow reversed can cause tool malfunction.
Connect the pressure (supply) hose and tank (return)
hose to the proper tool ports.
Failure to observe this warning could result in severe
injury or death.
Do not change accessories, inspect, adjust, or
clean tool when it is connected to a power source.
Accidental start-up can result in serious injury.
Failure to observe this warning could result in severe
injury or death.
• Inspect tool before use. Replace any worn or
damaged parts. A damaged or improperly assem-
bled tool can break and strike nearby personnel.
• Inspect the hydraulic hoses and couplings every
operating day. Repair or replace if leakage, crack-
ing, wear, or damage is evident. Damaged hoses
or couplings can fail, resulting in injury or property
damage.
• Use this tool for manufacturer’s intended use only.
Use other than that which is described in this
manual could result in injury or property damage.
Failure to observe these warnings could result in
severe injury or death.
IMPORTANT SAFETY INFORMATION

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
IMPORTANT SAFETY INFORMATION
• Do not operate the tool without a set of dies in
place. Damage to the ram or crimping tool head
can result.
• Maintain proper footing to prevent loss of balance
in case of unexpected movement of the crimping
tool.
• Do not perform any service or maintenance other
than as described in this manual. Injury or
damage to the tool may result.
Failure to observe these precautions may result in
injury and property damage.
Hydraulic oil can cause skin irritation.
• Handle the tool and hoses with care to prevent
skin contact with hydraulic oil.
• In case of accidental skin contact with hydraulic
oil, wash the affected area immediately to remove
the oil.
Failure to observe these precautions may result in
injury.
Procedure for connecting or disconnecting hydraulic
hoses, ttings, or components:
1. Move the ow lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Follow the sequence under “Hose Connections”
to prevent pressure buildup. In case some
pressure has built up, loosen hoses, ttings, or
components slowly.
Emergency stop procedure:
1. Release the trigger.
2. Shut off the hydraulic power source.
Note: Keep all decals clean and legible, and replace
when necessary.

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Identification
1. Crimping Head
2. Lock Pin
3. Cylinder
4. Trigger
5. Trigger Strap
6. Pressure (supply) Port
7. Tank (return) Port
8. Handle
1
8
2
45
3
7
6

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Specifications
LP6 Crimping Tool
Type of Hydraulic System: Open-center
or closed-center
Hydraulic Ports:
Pressure (supply): 3/4-16 UNF SAE O-ring Boss
Tank (return): 3/4-16 UNF SAE O-ring Boss
Noise Levels
LWA (Sound Power Level): 55.5 dB
LpCpeak (Peak Emission Sound Pressure Level):
68.8 dB
Vibration: 3.15 ms2
Crimping Force: 53 kN (6 tons)
Length:
With Couplers: 597 mm (23.50")
Without Couplers: 527 mm (20.75")
Width: 76 mm (3.00")
Depth: 165 mm (6.50")
Mass/Weight: 4.2 kg (9.25 lb)
Hydraulic Power Source
Do not exceed the following hydraulic power source
maximums:
• Hydraulic ow: 34.1 l/min (9 gpm).
• Pressure relief setting: 172 bar (2500 psi).
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.
Type of Hydraulic System: Open-center
or closed-center
Flow:
Minimum: 11.4 l/min (3 gpm)
Recommended: 22.7 l/min (6 gpm)
Maximum: 34.1 l/min (9 gpm)
Pressure Relief Setting:
Minimum: 103 bar (1500 psi)
Maximum: 172 bar (2500 psi)
Filtration: 10 micron (nominal)
Back Pressure (maximum*): 13.8 bar (200 psi)
* 13.8 bar (200 psi) is the maximum agreed standard back pressure
for the HTMA (Hydraulic Tool Manufacturers Association).
Greenlee Utility tools will operate satisfactorily at this standard.
1. Maximum hydraulic uid temperature must not
exceed 60 °C (140 °F). A sufcient oil cooling
capacity is needed to limit the hydraulic uid
temperature.
2. Hydraulic ow must not exceed 34.1 l/min (9 gpm).
Install a ow meter in the return line to measure the
rate of hydraulic ow before using the tool.
3. Pressure relief valve setting must not exceed
172 bar (2500 psi) at your tool’s maximum ow.
Locate the pressure relief valve in the supply circuit
to limit excessive hydraulic pressure to the tool.
Hydraulic Schematic
FILTER
(10 MICRON)
COOLER
RELIEF
VALVE
172 bar
(2500 psi)
CONTROL
VALVE FLOW METER
T
PTOOL
RESERVOIR
PUMP
POWER SOURCE
Recommended Hydraulic Fluids
Use any nondetergent, petroleum-based hydraulic
uid which meets the following specications or HTMA
specications.
S.U.S. @:
38 °C (100 °F): 140 to 225
99 °C (210 °F): 40 minimum
Flash Point: 170 °C (340 °F) minimum
Pour Point: –34 °C (–30 °F) minimum

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Hoses and Fittings
Installation and Maintenance
Refer to publication 99930323, SAE J1273
(Hose and Hose Assemblies).
Replacement
Refer to a Greenlee Utility catalog or publication
99910322, Low Pressure Quick Couplers, Adapters and
Hoses.
Do not disconnect tool, hoses, or ttings while the
power source is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Hose Connections
Tool Port Identification
Three methods are used to identify the pressure and
return ports of Greenlee Utility tools. Match the mark-
ings on your tool to this table.
Pressure Port Return Port
P T
or
In Out
or
3/4–16 O-ring Boss
Connecting Hoses
1. Move the ow control lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Connect the return hose to the return port on the
power source, and then to the return port on the
tool.
4. Connect the pressure hose to the pressure port on
the tool, and then to the pressure port on the power
source.
Disconnecting Hoses
1. Move the ow control lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Disconnect the pressure hose from the power
source, and then from the tool.
4. Disconnect the return hose from the tool, and then
from the power source.
Typical Setup

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Operation
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use only certied
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning
could result in severe injury or death.
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punc-
tures skin, causing serious injury,
gangrene, or death. If you are
injured by escaping oil, seek medical
attention immediately.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning
could result in severe injury or death.
An incomplete crimp can cause a re.
• Use proper die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
• The relief valve sounds to indicate a completed
crimp. If you do not hear the sound of the relief
valve, the crimp is not complete.
Failure to observe these warnings could result in
severe injury or death.
1. Refer to the connector manufacturer’s instructions
for cable preparation and the crimping procedure.
2. Center the connector between the dies or nibs.
3. Press the trigger to advance the dies or nibs.
• Press the trigger down completely for fast
advance.
• Press the trigger down partially for slow advance.
4. Continue crimping until the pressure relief valve
activates.
Note: Pressure relief is indicated by a change in the
sound from the crimping tool and a sudden stiffen-
ing of the hydraulic hoses.
5. After achieving pressure relief, release the trigger.
The dies retract.
6. Complete the number of crimps specied by the
connector manufacturer.
7. When the tool is not in use, stop the power source
to reduce heat and wear on tool components.

LP6 Hydraulic Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Operation (cont’d)
Die Selection
Interchangeable dies may be used in the standard die
opening. Dies that may be used include:
• Greenlee KD6 series
• Burndy W and X series
• ILSCO ND series
• Huskie HT58 series
• Panduit CD-2001 series
• Other industry W-type dies
Installing Dies
1. Select the proper dies for the connector to be
crimped.
2. Install dies in jaws making certain that they are
properly secured by the spring-loaded, positive
lock, die buttons.
Preparing Cable
Follow the lug manufacturer’s instructions for appropri-
ate cable strip length.
Crimping Direction
First Compression
Crimping Direction
SIDE A
Crimping Direction
SIDE B
First Compression
SIDE A
First Compression
SIDE B
Crimping Procedure
1. Insert conductor into the connector and align the
tool and die on the connector. Start in the center for
splices and “H” frames; and on the end, nearest the
pad, for terminals.
2. Activate the tool by pulling the trigger.
3. Continue crimping the connector until the correct
number of crimps has been completed. Work from
the center to the outer edges for splices and “H”
frame connectors, alternating sides if possible, for
the best compression connections.
An incomplete crimp can cause a re.
• Use proper die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
• The relief valve sounds to indicate a completed
crimp. If you do not hear the sound of the relief
valve, the crimp is not complete.
Failure to observe this warning could result in severe
injury or death.