Textron Greenlee LP6 GMA Series Manual de usuario

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

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

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

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

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

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

Identiﬁcation

1. Crimping Head

2. Lock Pin

3. Cylinder

4. Trigger

5. Trigger Strap

6. Pressure (supply) Port

7. Tank (return) Port

8. Handle

LP6 Hydraulic Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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

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

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

In Out

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

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

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.

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