OPERATION, SERVICE AND PARTS INSTRUCTION MANUAL GREENLEE FAIRMONT

Transcription

1 OPERATION, SERVICE AND PARTS INSTRUCTION MANUAL GREENLEE FAIRMONT DYNAPRESS INTENSIFIER H6704B, H6704B-1, H6706B, H6706B-1, H6708B, H6708B-1 H6710B, H6710B-1, H6710B-3, H6710B-4, Read and understand this material before operating or servicing this intensifier. Failure to understand how to safely operate this intensifier could result in an accident causing serious injury or death. This tool should only be operated by qualified personnel REV 2 (Replaces Bulletin 5047A) 1996 Greenlee Textron Inc. 10/96

2 GREENLEE FAIRMONT Dynapress Intensifier Table Of Contents OPERATION Safety Information Description... 5 Specifications - Dynapress Hydraulic Power Source... 6 Recommended Hydraulic Fluids... 6 System Hook-Up Schematic... 7 Hoses and Fittings... 8 Unit / Hose Connections Operation SERVICE Maintenance Schedule Troubleshooting Disassembly Assembly Unloading Relief Valve Setting MVU Snubber Removal/Instruction Reseating Check Ball Cavities PARTS Dynapress Optional Accessories APPENDICES Appendix A - SAE J1273 May DYNAPRESS is a registered tradename for hydraulic pressure intensifiers manufactured by Greenlee Fairmont. Additional or replacement manuals may be obtained from your Greenlee Fairmont distributor. When tool is received, complete the following record: SERIAL NUMBER: DATE OF PURCHASE: WHERE PURCHASED: Always mention the tool s serial number when ordering or writing about parts. For convenience in ordering, parts are listed by part number, description and quantity. If in doubt as to part needed, send a full description, sketch, or the part itself with the order. Assemblies are in CAPITAL letters, and include all component parts listed directly below them and indented to the right. When assemblies can be used, order them to save time assembling individual parts. Prior arrangements must be made before returning a tool for warranty service. To insure correct and prompt shipment of parts, always provide the following information when ordering: 1. Quantity of each part wanted 4. Serial Number of tool 2. Part number of item 5. Preferred method of shipment: by mail, UPS, or air freight 3. Description of part Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

3 GREENLEE FAIRMONT Dynapress Intensifier SAFETY ALERT SYMBOL Immediate hazards which WILL result in severe personal injury or death. The symbol above is used to call your attention to instructions concerning your personal safety. Watch for this symbol. It points out important safety precautions. It means ATTENTION! Become alert! Your personal safety is involved! Read the message that follows and be alert to the possibility of personal injury or death. Hazards or unsafe practices which COULD result in severe personal injury or death. Hazards or unsafe practices which COULD result in minor personal injury or property damage. Safety is a critical factor in the design of Greenlee Fairmont equipment. The best program starts with a safety-conscious operator. The information highlighted in this instruction manual describes operating practices for the benefit of the workers who will use our equipment in their daily jobs. Comments from users are appreciated. A person who has not read and does not understand all operating instructions is not qualified to operate this tool. Failure to read and understand safety instructions may result in severe injury or death. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

4 GREENLEE FAIRMONT Dynapress Intensifier Electrical Shock Hazard: When using this unit near energized electrical lines, use only certified non-conductive hoses. Select and maintain the hydraulic fluid to meet the minimum dielectric standards required by your safety department. Failure to observe this warning could result in severe injury or death. Skin Injection Hazard: High pressure oil easily punctures skin causing serious injury, gangrene or death. If injured seek medical help immediately to remove oil. Do not use fingers or hands to check for leaks. Depressurize hydraulic system before servicing. This unit operates at hydraulic pressures up to 10,000 psi. Use only hoses and fittings rated for 10,000 psi service on the high pressure end of the unit. Always stop pump/power source before connecting or disconnecting system components. Always depressurize hydraulic system (lowpressure and high-pressure) before disconnecting unit and/or system components. Do not disconnect system components, lines or fittings while pump/power source and/or if hydraulic fluid is hot. Exposure to hot hydraulic fluid can cause serious burns. Keep all parts of the body away from moving parts of crimping heads, cable cutters, or any other tool used with this unit. The owner of this unit must be certain that all users of this unit are adequately trained to safely use this unit for high-pressure applications in compliance with all appropriate industrial codes or standards. Use this unit for the manufacturer s intended purpose only. Inspect hydraulic hoses and couplings every operating day. Repair or replace if leakage, cracking, wear, or damage is evident. Use all appropriate and applicable personal safety equipment as required, such as: safety shoes, hard hat, safety glasses or face shield, etc. Observe and follow all safety rules and regulations for the job. Failure to observe these precautions could result in injury or property damage. Note: Keep all decals clean and legible. Replace decals when necessary with new decals listed in the Parts section of this manual. Failure to observe these warnings could result in severe injury or death. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

5 GREENLEE FAIRMONT Dynapress Intensifier Description The Dynapress is a piston pump type hydraulic pressure intensifier. The unit can be used with either Openor Closed-Center hydraulic systems to supply high pressure oil flow for operating tools which required low flow, high pressure hydraulic oil inputs, such as jacks, crimping heads, cable cutters, etc. Available in four different relief valve settings, from 4,000 psi to 10,000 psi, the Dynapress can be installed in an existing hydraulic system because it does not require a third hydraulic line or separate reservoir. The compact and lightweight design allows the unit to be easily carried and used on the ground or aloft in an aerial lift basket. Remote Control Valve - Actuating the high pressure end of the Dynapress requires the use of a remote control valve. Either a single- or double-acting remote control may be used. Model Numbers - The model number of your Dynapress is shown on the serial number plate, located between the low pressure ports of the Dynapress. Models with the suffix of B are referred to in this manual as B models, B1, are B1 models, etc. Unit and Tool - Unit or intensifier, as used in this manual, refers to the Dynapress; tool refers to the crimping head, cable cutter, or other tool used with the Dynapress. Specifications - Dynapress Weight lbs. (7.48 kg) Height in. (19.69 cm) Length in. (33.66 cm) Width in. (11.43 cm) Pressure - Power Source psi ( bar) Flow - Power Source gpm ( L/min) Output Fast Advance Mode in 3 /min (4999 cm 3 /min) High Pressure Mode B models in 3 /min (328 cm 3 /min) B1 models in 3 /min (656 cm 3 /min) B3 models in 3 /min (328 cm 3 /min) B4 models in 3 /min (656 cm 3 /min) in 3 /min (656 cm 3 /min) Relief Valve Setting H6704B H6704B psi (276 bar) H6706B, H6706B1... 6,000 psi (414 bar) H6708B, H6708B1... 8,000 psi (593 bar) H6710B, H6710B1, H6710B3, H6710B4, ,000 psi (690 bar) Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

6 GREENLEE FAIRMONT Dynapress Intensifier Specifications - Hydraulic Power Source Power source flow must not exceed 8 gpm. Limit relief pressure to 2000 psi. Failure to observe these warnings could result in over-pressurizing the system, causing severe injury to operator or bystanders. Any hydraulic power source used with this unit must meet the following requirements: Type of Hydraulic System... Open- or Closed-Center Filtration micron (nominal) Flow - Minimum... 3 gpm (11 l/m) - Maximum... 8 gpm (30 l/m) Pressure Relief Setting psi (138 bar) Back Pressure - *Maximum psi (14 bar) * 200 psi is the maximum agreed standard for the Hydraulic Tool Manufacturers Association (HTMA). Greenlee Fairmont tools operate satisfactorily at this standard. 1. Maximum fluid temperature must not exceed 140 F (60 C) at the maximum expected ambient temperature. A sufficient oil cooling capacity is needed to limit the fluid temperature. 2. Maximum flow must not exceed 8 gpm. Install a flow meter in the return line to test the rate of flow in the system before working the tool. 3. Pressure relief valve must not exceed 2000 psi. The pressure relief valve must be located in the supply circuit between pump and Dynapress to limit excessive pressure to the tool. Figures 1 & 2 show a typical hydraulic power source being used with the unit when connected to single- and doubleacting tools. Recommended Hydraulic Fluids Any non-detergent oil which meets the following specifications may be used. 100 F (38 C) to 210 F (99 C) minimum Flash Point (min.) F (170 C) Pour Point (min.) F (-34 ) Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

7 GREENLEE FAIRMONT Dynapress Intensifier Figure 1 System Hook-Up Schematic Single-Acting FILTER RESERVOIR RELIEF VALVE 2000 PSI COOLER T T POWER SOURCE PUMP P CONTROL VALVE INTENSIFIER P REMOTE CONTROL VALVE P TOOL Figure 2 System Hook-Up Schematic Double-Acting FILTER RESERVOIR RELIEF VALVE 2000 PSI COOLER T T R POWER SOURCE PUMP P CONTROL VALVE INTENSIFIER P REMOTE CONTROL VALVE P TOOL Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

8 GREENLEE FAIRMONT Dynapress Intensifier Hoses and Fittings Use only hoses and fitting rated for 10,000 psi service on the high pressure end of the unit. Hoses and fittings used with this tool must comply with SAE Standard J1273 (See Appendix A) recommended practice for selection, installation and maintenance of hose and hose assemblies. Failure to observe these warnings could result in severe injury or death. Certified non-conductive 10,000 psi high pressure hose assemblies and couplers are available from Greenlee Fairmont as accessories. See the Parts section of this manual or contact an authorized Greenlee Fairmont distributor for certified non-conductive 10,000 psi high-pressure hoses and couplers. Electrical Shock Hazard: When using this unit near energized electrical lines, use only certified non-conductive hoses. Select and maintain the hydraulic fluid to meet the minimum dielectric standards required by your safety department. Failure to observe this warning could result in severe injury or death. Skin Injection Hazard: High pressure oil easily punctures skin causing serious injury, gangrene or death. If injured seek medical help immediately to remove oil. Do not use fingers or hands to check for leaks. Depressurize hydraulic system before servicing. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

9 GREENLEE FAIRMONT Dynapress Intensifier Unit/Hose Connections Always stop pump/power source before connecting or disconnecting system components. Always depressurize hydraulic system (lowpressure and high-pressure) before disconnecting unit and/or system components. Failure to observe these warnings could result in severe injury or death. Connecting Hoses (See Figure 3) Note: The Dynapress, remote control valve and tool should always be connected together before any connection is made to the hydraulic power source. 1. Stop the power source. 2. Connect return (tank) hose from remote control valve to Dynapress high pressure port T. Note: Return (tank) hose connection should always be made before supply (pressure) hose connection, to prevent pressure build-up inside unit. 3. Connect supply (pressure) hose from remote control valve to Dynapress high pressure port P. 4. Connect tool to be used (i.e., crimping head, cable cutter, etc.) to remote control valve, either directly to the coupler or through high pressure hose. 5. Connect tank (return) hose from power source to Dynapress low pressure port T. 6. A control valve should be located in the supply line between power source and Dynapress. 7. Connect supply (pressure) hose from power source to Dynapress low pressure port P. Note: When the Dynapress is not in use, oil flow should be shut off at the control valve between the pump/power source and the Dynapress, to reduce heat and wear to the Dynapress and remote control valve. Disconnecting Hoses (See Figure 3) Note: The Dynapress, remote control valve, and tool should always be connected together before any connection is made to the hydraulic power source. 1. Stop the power source. 2. Disconnect tool (i.e., crimping head, cable cutter, etc.) from remote control valve. 3. Disconnect supply (pressure) hose from power source to Dynapress low pressure port P. Note: Supply (pressure) hose connection should always be disconnected before return (tank) hose connection to prevent pressure build-up inside unit. 4. Disconnect tank (return) hose from power source to Dynapress low pressure port T. 5. Disconnect supply (pressure) hose from remote control valve to Dynapress high pressure port P. 6. Disconnect return (tank) hose from remote control valve to Dynapress high pressure port T. 7. To prevent contamination, always install dust caps over the hydraulic ports of the intensifier when disconnected. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

10 GREENLEE FAIRMONT Dynapress Intensifier Figure 3 Unit/Hose Connections POWER SOURCE 2,000 PSI FLOW ON/OFF VALVE T P T MEDIUM PRESSURE HOSES T P P INTENSIFIER 4,000-10,000 PSI FLOW & PRESSURE TEST GAUGE (FOR INSPECTION ONLY) FLOW ON/OFF VALVE HIGH PRESSURE PUMP 4,000-10,000 PSI P T ,000 PSI HIGH PRESSURE TEST GAUGE (FOR INSPECTION AND/OR ADJUSTMENT OF UNLOADING VALVE ONLY) T T VALVE P P HIGH PRESSURE HOSES SYMBOL FOR DISCONNECT COUPLER HIGH PRESSURE HOSES T P TOOL DIRECT COUPLING T P TOOL REMOTE COUPLING Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

11 GREENLEE FAIRMONT Dynapress Intensifier Operation Electrical Shock Hazard: When using this unit near energized electrical lines, use only certified non-conductive hoses. Select and maintain the hydraulic fluid to meet the minimum dielectric standards required by your safety department. Failure to observe this warning could result in severe injury or death. Use this unit for the manufacturer s intended purpose only. Use all appropriate and applicable person safety equipment as required, such as: safety shoes, hard hat, safety glasses or face shield, etc. Observe and follow all safety rules and regulations for the job. Failure to observe these precautions could result in injury or property damage. Keep all parts of the body away from moving parts of crimping heads, cable cutters, or any other tool used with this unit. The owner of this unit must be certain that all users of this unit are adequately trained to safely use this unit for high-pressure applications in compliance with all appropriate industrial codes or standards. Failure to observe these warnings could result in severe injury or death. Pre-Operation 1. Stop the power source. 2. Connect desired tool to remote control valve. Connect hydraulic hoses from remote control valve to intensifier, and from intensifier to pump/power source. Start the power source. 3. Place intensifier in a convenient location. If working from an aerial lift basket, the unit will fit inside the basket. 4. It is recommended that the power source be allowed to run (idle) for a few minutes to warm the hydraulic reservoir fluid. Actuating the remote control valve intermittently will reduce the time required to warm the fluid to an efficient operating temperature. Operation 1. To actuate the high-pressure tool, depress the remote control valve trigger in the desired direction. As the pressure builds above 2000 psi, the remote control valve is locked in the actuated position, and the operator may release the trigger. 2. When system pressure reaches the setting of the unloading valve (4,000 or 10,000 psi, depending on model), the high pressure oil will then dump back to tank, and drop system pressure to nearly zero psi. The remote control valve trigger will release and return to the neutral position, and the ram in the high-pressure tool retracts. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

12 GREENLEE FAIRMONT Dynapress Intensifier Maintenance The service life of the Dynapress will be maximized by proper care and maintenance. The maintenance schedule below is recommended. Daily: 1. Wipe all tool surfaces clean of dirt and foreign material. Inspect hoses and fittings for signs of leaks, cracks, wear or damage. Replace if necessary. 2. Check hydraulic reservoir level. Fill to correct level if low. 3. To prevent contamination, always install dust caps over couplers when Dynapress is disconnected. Monthly: 1. Perform a detailed inspection of hoses and fittings as stated in Appendix A - S.A.E. Standard J1273, May, Replace hoses and fittings if necessary. 2. Change hydraulic system filter to keep fluid in the system clean. Semi-annually: 1. Drain the hydraulic system fluid. Flush out the hydraulic system and fill with new, clean fluid. The unloading valve setting should be checked periodically to insure that the correct pressure is being reached. Visual inspection of crimps or cuts may indicate that adjustment is necessary. Install a non-filled pressure gauge for fast response, in place of tool, and actuate the intensifier to check relief setting. (See Parts section for non-filled pressure gauge.) If adjustment is necessary, see Unloading Valve Relief Setting. The Dynapress is self-lubricating. Changing system filters regularly to keep fluid in the system clean will allow proper lubrication and extend the service life of the Dynapress. Disconnect the Dynapress from the remote control when storing the unit. Do not kink hoses when storing. Reseating of check ball cavities, unloading valve adjustment, and disassembly should be done only when required to repair improperly operating or damaged unit. If unit does not operate properly, check Troubleshooting chart, before attempting an overhaul. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

13 GREENLEE FAIRMONT Dynapress Intensifier Troubleshooting Determining the Problem Area Before troubleshooting this unit, it may be necessary to pinpoint either the pump/power source, the intensifier unit itself, or the remote control valve as the problem area. The following steps will help to determine the source of the problem. See Specifications section for power source requirements. 1. With no tool attached to the remote control valve, disconnect the tank (return) line between remote control and Dynapress, at the Dynapress. Remove the quick coupler nipple from the return hose, so that oil can flow freely into a bucket. 2. With remote control valve in neutral position (not engaged), supply power to the system, starting the Dynapress. Oil should flow through the disconnected return line into the bucket. 3. Actuate and hold the remote control valve in the advance position. No oil flow from the return line at this time indicates that the problem is likely to be in the Dynapress. If oil continues to flow from the return line, the problem is likely to be in the remote control valve. For troubleshooting Greenlee Fairmont single-acting remote control valves, contact your authorized Greenlee Fairmont distributor. PROBLEM PROBABLE CAUSE POSSIBLE REMEDY Dynapress will not start. Coupler connection to power source or Relieve pressure, reverse couplers oil flow reversed. OR change direction of flow from supply. Connection to tool circuit not complete. Insufficient supply pressure. Improper torque on motor housing bolts. Foreign material in drive assembly (gerotors, drive shaft, etc.) Improper placement of parts after service. Ball seat in tank port of low pressure end of motor housing assembly loose or backed out. Relieve pressure and complete connection. Increase supply pressure to psi. Torque the 8 bolts on low pressure end of Dynapress to 125 in/lbs. Disassemble, inspect and clean. Disassemble and inspect, reviewing assembly procedure. Retighten ball seat. Unit operates erratically. High pressure pump base - check ball Remove, flush, and reseat check or check ball seats damaged OR 2 balls. Replace if damaged. check balls in 1 high pressure cavity. Cracked check balls. Replace check balls. Orifice (.020) of metering screw in Remove metering screw and clean high pressure pump base partially orifice to.020". blocked. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

14 GREENLEE FAIRMONT Dynapress Intensifier Troubleshooting (cont d) PROBLEM PROBABLE CAUSE POSSIBLE REMEDY Tool extends and retracts, but Unloading valve leaking around copper Torque unloading valve to 350 in/lbs unit does not build pressure, washer seat. (29 ft/lbs). or builds pressure slowly. Unloading valve leaking internally. Foreign material plugging metering screw. Foreign material in high pressure check cavities. Damaged check ball seats. Foreign material in inlet check cavities. Damaged inlet seats. Foreign material in fast advance check cavity. Damaged fast advance check. Improper placement of parts after service. Disassemble, clean and inspect. Remove motor outlet check ball in motor housing. Reverse flow to Dynapress momentarily to flush metering screw. Replace check ball OR disassemble and clean or replace metering screw. Remove, flush, and reseat check balls. Replace if damaged. Disassemble, flush and reseat inlet checks. Replace if damaged. Disassemble, flush, and reseat fast advance check. Replace if damaged. Disassemble and inspect, reviewing assembly procedure. Tool does not retract. Excessive back pressure. Reduce input gpm or alter power source return system to recommended back pressure or less. Improper or damaged coupler connection. Damaged tool being used. Worn scavenger pump housing. Improper torque on motor housing bolts. Improper placement of parts after service. Relieve pressure, correct connection or replace coupler. Inspect and repair or replace tool. Replace. Torque the 8 bolts on low pressure end of Dynapress to 125 in/lbs. Disassemble and inspect, reviewing assembly procedure. Pressure does not reach Unloading valve leaking around copper Torque unloading valve to 350 in/lbs unloading valve setting. washer seat. (29 ft/lb). Unloading valve leaking internally. Disassemble, clean and inspect. Re-adjust unloading valve pressure to match Dynapress model relief setting after re-installing. See Adjusting Unloading Valve. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

15 GREENLEE FAIRMONT Dynapress Intensifier Troubleshooting (cont d) PROBLEM PROBABLE CAUSE POSSIBLE REMEDY Pressure does not reach Improper torque on motor housing Torque the 8 bolts on low pressure unloading valve setting (cont d) bolts. end of Dynapress to 125 in/lbs. External high pressure leak. Tighten connection or replace hose. Use pipe thread sealant if necessary. Skin Injection Hazard: High pressure oil easily punctures skin causing serious injury, gangrene or death. If injured seek medical help immediately to remove oil. Do not use fingers or hands to check for leaks. Depressurize hydraulic system before servicing. Internal high pressure oil leak. Damaged O-ring. Foreign material in high pressure check cavities. Damaged check ball seats. Foreign material in inlet check cavities. Damaged inlet seats. Foreign material in fast advance check cavity. Damaged fast advance check. Worn or damaged motor housing. Disassemble. Replace O-ring on high pressure pump base. Remove, flush and reseat check balls. Replace if damaged. Disassemble, flush and reseat inlet checks. Replace if damaged. Disassemble, flush, and reseat fast advance check. Replace if damaged. Replace. Remote control does not return High oil temperature or incorrect See fluid recommendations. to neutral position. hydraulic fluid. Remove snubber from unloading valve. See MVU Snubber Removal/ Installation. Foreign material in unloading valve orifice. Unloading valve malfunction. Not dropping to near zero psi. Remove and clean or replace orifice. Disassemble and inspect; repair or replace. Unit cycles only once. Cold oil. Run unit to warm system oil to operating temperature. Actuating tool intermittently will reduce warm-up time. Install snubber assembly into unloading valve. See MVU Snubber Removal / Installation. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

16 GREENLEE FAIRMONT Dynapress Intensifier Troubleshooting PROBLEM PROBABLE CAUSE POSSIBLE REMEDY Unit cycles only once. (cont d) Excessive back pressure. Reduce input gpm or alter power source return system to recommended back pressure or less. A flow restrictor plug may be used in pressure port on low pressure end of the unit, such as Fairmont Hydraulics # Unit unloads before desired Unloading valve setting low. Adjust unloading valve pressure to pressure is reached. match Dynapress model relief setting. See Adjusting Unloading Valve. Replace if necessary. Do not adjust more than 1/2 turn at a time! Unloading valve body damaged or worn. Disassemble, clean and inspect. Re-adjust unloading valve pressure to match Dynapress model relief setting after re-installing. See Adjusting Unloading Valve. Unit stalls before desired Improper torque on motor housing Torque the 8 bolts on low pressure pressure is reached. bolts. end of Dynapress to in/lb. Leakage in motor cavity due to foreign material. Insufficient supply pressure. Replace motor housing. Increase supply pressure to psi. Unit cycles rapidly, but remote Improper connection between unit Relieve pressure, complete control and tool do not function. and remote control. connection. Damaged high pressure coupler. Replace coupler. Tool extends on start-up and Foreign material in drive assembly Disassemble, inspect and clean. will not retract. (gerotors, drive shaft, etc.). Improper placement of parts after service. Improper coupler connection. Disassemble and inspect, reviewing assembly procedure. Check connection. Re-tighten if necessary. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

17 GREENLEE FAIRMONT Dynapress Intensifier Disassembly COMPLETE DISASSEMBLY OF INTENSIFIER UNIT IS NOT RECOMMENDED. RETURN UNIT TO YOUR NEAREST AUTHORIZED GREENLEE FAIRMONT HYDRAULICS DISTRIBUTOR OR TO THE FACTORY. The disassembly procedure is divided into sections of the unit. Complete disassembly of the unit is seldom necessary. Disassemble only the area(s) necessary to correct the problem. See Parts Illustrations for identification of parts as they are removed. Disassembly should be done on a flat, clean surface. Some of the parts may fall free during disassembly. To prevent part loss or damage, keep the tool as close to the working surface as possible. Inspect all parts as they are disassembled (and mating parts in the unit that are not removed) for signs of damage, wear, cracks, etc. Replace any parts which appear to be damaged. When removing O-rings which must slide over sharp surfaces, be careful not to damage the O-rings. Use a rolling motion, and apply hydraulic fluid to ease removal of O-rings if necessary. When disconnecting system components, removing hydraulic lines, fittings, or components the following procedure must be adhered to: Stop the power source. Always wear appropriate personal safety equipment. Depressurize the hydraulic system. Disconnect hydraulic hoses from unit. Do not remove fittings or components when hydraulic fluid is hot. Exposure to hot hydraulic fluid can cause serious personal burns. Remove lines, fittings or components slowly to release any trapped pressure. If injury results from escaping fluid, see a doctor at once; serious reaction or infection may result if proper medical attention is not obtained immediately. Failure to observe these warnings could result in severe injury or death. Note: If the outer intensifier parts do not come apart easily at disassembly, tap lightly with a rubber or plastic hammer to separate them. Do not use a metal hammer, and do not strike any part of the intensifier too hard, or damage will result. Intensifier 1. See Figure 12. Remove return (male) coupler (6) from high pressure end of unit to allow removal of the intensifier from the housing assembly (1). 2. See Figure 11. Remove button head socket cap screws (2) and spacers (3). Remove intensifier (4) from housing (1). Using a sharp object, scribe a line along the length of the intensifier to align parts correctly during assembly. 3. See Figure 11. Remove motor inlet spacer (41) from low pressure intensifier port P. Remove O-ring (39) from motor inlet spacer. Remove motor outlet check valve (40) and check ball (36) from low pressure intensifier port T. Remove O-ring (39) from motor outlet check valve. High Pressure Pump Head 1. See Figure 11. Remove socket head cap screws (34) from high pressure pump head (32). Remove high pressure pump head from intensifier. 2. See Figure 11. Remove dowel pin (10), and O-ring (33). Place high pressure pump head (32) in a vise with ports up. Protect pump head from vise jaws with a cloth, and DO NOT TIGHTEN EXCESSIVELY. High pressure pump head is aluminum, and should be handled with care. 3. See Figure 12. Remove hex nipple (4) from high pressure pump head port T. Remove female coupler (5) and in-line port adapter (3) from high pressure pump head port P. These parts are held with pipe thread sealant, rated at 10,000 psi, and may not break free easily. Remove O-ring from inside female coupler assembly. Unloading Valve and Snubber 1. See Figure 11. Remove relief valve cap (38). Remove O-ring (37) from relief valve cap. Remove unloading valve assembly (35) from high pressure pump head. 2. See Figure 14. Remove orifice assembly (8) from unloading valve assembly (1). Remove body (10). Spring (12), ball pintle (11), and ball (13) will fall free of ball retainer (9). 3. See Figure 14. Remove gasket (7) from unloading valve body (2). Remove spring cup retainer (5). Spring (4) and pintle (3) may be removed by tapping female body (2) lightly on the working surface. The pintle will not come free from body (2) if the snubber (8) has not been removed. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

18 GREENLEE FAIRMONT Dynapress Intensifier Disassembly (cont d) Unloading Valve Assembly (48395 only) 1. See Figure 11. Remove relief valve cap (38), and remove O-ring (37) from relief valve cap. Remove unloading valve assembly (35) from high pressure pump head. 2. See Figure 15. Remove unloading valve gasket (7) from unloading valve assembly. Remove set screw (6) from unloading valve body (1). Remove spring cup retainer (5). Unloading valve spring (4), pressure relief pintle (3), and ball (2) may be removed by tapping female threaded end of unloading valve body lightly on the working surface. High Pressure Pump Base Note: See Figure 5. Take special care to prevent pump pistons from falling out of high pressure pump base assembly (29). Each piston is matched to its bore in the pump base at the factory. If pistons should accidentally fall out of the assembly, be careful to return each piston to the correct bore. Figure 5 High Pressure Pump Base PUMP PISTON HIGH PRESSURE PUMP BASE 1. See Figure 11. Remove the 8 long bolts (31) and copper washers (30) from the low pressure end of the intensifier. 2. Remove high pressure pump base assembly (29) from intensifier. Remove dowel pin (10). See Figure 10. Remove O-rings (9 through 12) and metering screw (8). Note: If the check balls within the high pressure pump base need removal or reseating, see Reseating Check Ball Cavities, and refer to that particular check area for disassembly instructions. Note: Never attempt to remove or adjust back-up unloading valve or return check. Servicing these parts requires special tools. If repairs become necessary, return unit to your authorized Greenlee Fairmont distributor or to the factory. Wobble Plate 1. See Figure 11. Remove wobble plate housing (28) from intensifier assembly. Remove dowel pin (10). Remove O-rings (6 & 12) from wobble plate housing. There will be a total of five O-rings in wobble plate housing. 2. Remove set screw(s) (27) from wobble plate (26). Note: May be 1 or 2 screws depending on model year. Lift wobble plate, two thrust washers (23), and needle thrust bearing (24) from drive shaft (8). Remove dowel pin (25) from drive shaft. Scavenger Pump 1. See Figure 11. Remove scavenger pump body (11) from intensifier assembly. Drive shaft (8) will remain within scavenger pump body. Locking ball(s) (9) may fall free at this time. Note: Earlier models have two locking balls, while newer models have only one ball. If your unit is an earlier model, one of the locking balls may be discarded. Only one ball is required at re-assembly. 2. Holding scavenger pump body in your hand, lightly tap drive shaft end which has locking ball indentation(s). Dowel pin (19) will push pump body cover (21) out the opposite end of the scavenger pump body. 3. Remove O-rings (22) from pump body cover (21). Remove inner and outer sections of gerotor set (20) from scavenger pump body. 4. With dowel pin (19) still in place, lightly tap drive shaft end which has locking ball indentation(s). This will push distributor ring (13) out the opposite end of the scavenger pump body. 5. Remove two dowel pins (10). Remove backup ring (14) and O-rings (15-18) from distributor ring (13). Remove O-ring (12) from scavenger pump body (11). 6. Remove inner and outer sections of gerotor set (7) from motor housing assembly (5). Remove O-rings (15) and backup ring (14) from center cavity of motor housing assembly. Remove two O-rings (6) from counterbores of motor housing assembly. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

19 GREENLEE FAIRMONT Dynapress Intensifier Assembly Inspection 1. Unloading Valve (1 - Figure 14): If the unloading valve was removed, a new copper gasket (7) must be installed at assembly. Spring (4) must not be fatigued. If so, replace spring. Mating surfaces of body (2) and pintle (3) must be smooth and free of grooves or nicks. If not, replace component. 2. Wobble Pate (26): Wobble plate surfaces must be smooth and free of grooves, nicks or cracks. If not, replace the wobble plate. Thrust bearing and washers on wobble plate assembly must have a smooth motion with no rough spots. If not, replace the wobble plate complete as an assembly. 3. Thrust Bearing (24): Install one thrust washer (23), thrust bearing (24), and the remaining thrust washer (23) onto wobble plate (26). Slide wobble plate into pump body cover (21). Hold pump body cover in one hand and spin the wobble plate with your other hand. Motion should be smooth with no rough spots. If not, replace the bearing or washers. 4. High Pressure Pump Base (29): All components, cavities, and passageways must be smooth and free of grooves, nicks, or cracks. If not, replace component. If pistons in high pressure pump base are damaged, replace pump base complete as an assembly. 5. Gerotor Sets (7 & 20): All surfaces in the gerotor set must be smooth and free of grooves, nicks, or cracks. If not, replace the component. 6. O-Rings and Back-up Rings: Always replace O-rings and back-up rings in components that have been disassembled with new O-rings and back-up rings during assembly. A packing kit is available that includes all O-rings and back-up rings. 7. Check Balls (1 - Figure 13): Any removed check ball must be discarded and not re-used. New check balls must be installed at assembly. Two new check balls are required for each cavity in the valve body, one for the seating procedure (then discard) and one for installation. 8. Springs (2 & 15 - Figure 13): The compression springs in the check ball cavities must not be fatigued. If so, replace spring. 9. Female and Male Couplers (5 & 6 - Figure 12): The mating surfaces of couplers must be smooth and free of grooves or nicks. If not, replace the coupler. Assembly When assembling parts, refer to Parts Illustrations for correct orientation and placement of parts. Clean all parts with solvent (take care to protect eyes), then dry thoroughly. Do not expose O-rings or other packing components to solvent for long periods of time. Inspect all parts as they are assembled for signs of damage, wear, cracks, etc. Do not install any parts which appear to be damaged. Apply hydraulic fluid or O-ring lubricant to all O-rings and all metal surfaces which O-rings must slide over. When installing an O-ring over a sharp edge, use a rolling action to avoid damage to O-ring. Wherever assembled parts cause metal to metal contact, coat the surfaces with petroleum jelly or O-ring lubricant. Note: See Figure 6. Dowel pins are used throughout assembly to help align and secure parts in the correct position. Care should be taken to place dowel pins only into the alignment holes of components and not into oil ports or holes drilled through the length of parts, which may have diameters similar to dowel pin alignment holes. Figure 6 shows a typical end view of a part. Note that two oil ports are diametrically opposite one another, and there is no hole diametrically opposite the dowel pin alignment hole. Figure 6 Dowel Pin Placement DOWEL PIN ALIGNMENT HOLE OIL PORT OIL PORT BOLT HOLES Scavenger Pump 1. See Figure 11. Set motor housing assembly (5), port side down, on a flat, clean surface. Install backup ring (14) and O-ring (15) in center cavity of motor housing assembly. Install one O-ring (6) in each of two 5/16" counterbores. 2. Install outer and inner sections of gerotor set (7) into cavity in top of motor housing assembly (5). Gerotor set must be.001/.003" below inner surface of motor housing assembly. Refer to Figure 7. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

20 GREENLEE FAIRMONT Dynapress Intensifier Assembly (cont d) 3. Newer Models Only: Install locking ball (9) into rounded cavity in drive shaft (8). Earlier Models Only: Earlier models have two rounded cavities in the drive shaft. Take care to install ONLY ONE locking ball (9) into rounded cavity CLOSEST to the end of drive shaft (8). 4. Slide drive shaft into previously assembled parts, aligning locking ball with rounded slot of inner gerotor section. 5. See Figure 11 - Detail A-A. Place dowel pin (10) into each alignment hole in the scavenger pump body (11). Install backup ring (14) and O-rings (15-18) in distributor ring (13). Install distributor ring into scavenger pump body, guiding inner dowel pin (10) in scavenger pump body into the alignment hole in the distributor ring. Apply pressure until distributor ring is flush with scavenger pump body. 6. Install O-ring (12) onto scavenger pump body, then slide scavenger pump (11) onto drive shaft (8). Insert dowel pin (19) into drive shaft, using long (needle) nosed pliers. 7. Install outer and inner sections of gerotor set (20) into cavity in top of scavenger pump body (11). Gerotor set must lie.001/.003" below Surface A. Refer to Figure Install O-rings (22) onto outside of pump body cover. Install pump body cover (21), flat side down, into scavenger pump body. Apply pressure until upper edge of pump body cover is flush with scavenger pump body. Install dowel pin (25) into drive shaft (8). Figure 7 Gerotor Installation.001/.003 Wobble Plate 1. Install one thrust washer (23), needle thrust bearing (24), and second thrust washer (23) on wobble plate assembly (26). Slide wobble plate assembly onto drive shaft, making sure to align groove in wobble plate (26) with dowel pin (25). 2. See Figure 8. Using long (needle) nosed pliers, grasp dowel pin (1) inside the hollow drive shaft (2). While holding wobble plate and intensifier assembly down, adjust the drive shaft so that it protrudes 1-5/16" (33.3mm) from the distributor ring assembly (3). Note: Drive shaft MUST protrude from distributor ring 1-5/16" (33.3mm). If drive shaft protrudes too little or too much, serious damage may result to the intensifier. Earlier Models Only: Tighten first set screw (27), locking drive shaft in protruded position. Install and tighten second set screw (27). Newer Models Only: Tighten set screw (27), locking drive shaft in protruded position. 3. Install O-ring (12) onto wobble plate housing (28). Install O-rings (6) into the four counterbores located on the ends of wobble plate housing. 4. Insert one dowel pin (10) in the alignment hole in the top of scavenger pump body (11). Install wobble plate housing (28) onto scavenger pump body (11), making sure to guide the alignment hole in the wobble plate housing over the dowel pin. Note: All eight bolt holes around the outer edge of the intensifier should be unobstructed from end to end. If any of the bolt holes are obstructed, disassemble intensifier, checking orientation of parts. Check dowel pin (10) locations. See Figure 11. Figure 8 Driveshaft Placement SURFACE A 1-5/16 Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

21 GREENLEE FAIRMONT Dynapress Intensifier Assembly (cont d) High Pressure Pump Base Notes: 1. See Figure 5. Take special care to prevent pump pistons from falling out of high pressure pump base assembly (29). Each piston is matched to its bore in the pump base at the factory. If pistons should accidentally fall out of the assembly, be careful to return each piston to the correct bore. 2. Never attempt to remove or adjust back-up unloading valve or return check. Servicing these parts requires special tools. If repairs become necessary, return unit to your authorized Greenlee Fairmont distributor, or to the factory. 3. If the check balls within the high pressure pump base were removed or reseated, see Reseating Check Ball Cavities, and refer to that particular check area for assembly instructions. 1. See Figure 13. Install metering screw (8). Torque to 15 in/lb. Install O-rings (9-12) as illustrated. 2. See Figure 11. Insert dowel pin (10) into the alignment hold on top of wobble plate housing (28). Install high pressure pump base assembly (29), guiding the alignment hole over the dowel pin. 3. Carefully turn intensifier on its side. Install one copper washer (30) on each of the eight long bolts (31). Install bolts into intensifier assembly, tightening by hand, just enough to hold intensifier together. Unloading Valve and Snubber 1. See Figure 14. Insert pintle (3) into unloading valve body (2), seating the pointed end. Place spring (4) inside pintle (3). Screw spring cup retainer (5) into unloading valve body (2). Install set screw (6) loosely into either of the two threaded holes in the unloading valve body. Do not tighten spring cup retainer into unloading valve body. Screw in only enough to hold parts together - until spring just begins to compress. Over-tightening may set unloading valve relief above recommended levels. Failure to observe this warning could result in severe injury or death. 2. Install spring (12), pintle (11), and ball (13) into body (10). Screw ball retainer (9) onto body (10), and tighten by hand. Install snubber assembly (8) into unloading valve assembly (1). Torque to in/lb. Install gasket (7) on unloading valve assembly. Unloading Valve Assembly (48395 only) 1. See Figure 15. Unloading valve assembly: Insert ball (2) and pintle (3) into unloading valve body (1). Place spring (4) on pintal (3). Screw spring cup retainer (5) into unloading valve body (1). Install set screw loosely (just until threads catch) into either of the two #8 (.164") tapped holes in the unloading valve body. Do not tighten spring cup retainer into unloading valve body. Screw in only enough to hold parts together - until spring just begins to compress. Over-tightening may set unloading valve relief above recommended levels. Failure to observe this warning could result in severe injury or death. Note: Relief setting is NOT adjusted at this point. Install unloading valve gasket (7) on unloading valve assembly. High Pressure Pump Head 1. See Figure 11. Place high pressure pump head (32) in a vise with ports up. Protect pump head from vise jaws with a cloth, and DO NOT TIGHTEN VISE EXCESSIVELY. High pressure pump head is aluminum, and should be handled with care. Install unloading valve assembly (35) in high pressure pump head. Torque to 350 in/lb (29 ft/lb). 2. See Figure 12. Apply pipe thread sealant to male threads of in-line port adapter (3), install and tighten in high pressure pump head port P. Install O-ring in female coupler (5). Install female coupler (5) into in-line port adapter (3). Note: When tightened, female coupler (5) must be oriented with one wrench flat directly facing unloading valve assembly. Note: Relief setting is NOT adjusted at this point. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

22 GREENLEE FAIRMONT Dynapress Intensifier Assembly (cont d) 3. Apply pipe thread sealant to male threads of in-line port adapter (3) on T port of pump head. Install return (male) coupler (6) onto port adapter. Note: When tightened, return coupler (6) must be oriented with one wrench flat directly facing unloading valve assembly. 4. See Figure 11. Remove high pressure pump head from vise. Install O-ring (33) into counterbore. Install dowel pin (10) into the alignment hole in high pressure pump base (29). Install high pressure pump head (32) onto intensifier, guiding the alignment hole over dowel pin. 5. Install socket head cap screws (34) into high pressure pump head (32). Tighten just enough to hold assembly together. Install O-ring (39) on relief valve cap (38). Install relief valve cap over unloading valve assembly and hand-tighten. Intensifier 1. Place intensifier horizontally in bench vise (couplers parallel to the floor). Clamp only on the pump head (32) and pump base (29). Note: Clamping differently than instructed above may cause improper compression of parts and unit failure. 2. See Figure 9. Torque eight long bolts (31) to in/lb. in sequence shown Figure 9 Torque Sequence Using a crisscross pattern, torque socket head cap screws (34) to in/lbs in 25 in/lb increments. 4. Install O-ring (39) on motor inlet space (41). Install motor inlet space in low pressure intensifier port P and tighten. Install O-ring (39) on motor outlet check valve (40). Install check ball (36) in low pressure intensifier port T. Install outlet check valve over check ball and tighten. 5. Connect intensifier to hydraulic power unit as instructed in Unit/Hose Connections. Connect high pressure couplers to remote control and tool, placing pressure test gauge in supply pressure line. Hydraulic oil under pressure: Before operating tool with the housing removed, cover it with 1/4" plastic (such as plexiglass). Oil and/or parts may be released during operation. Failure to observe this warning could result in severe injury or death. Start up unit to verify proper operation. Unit may unload before desired pressure is reached; this is acceptable at this point in the assembly. If unit does not operate correctly, refer to Troubleshooting chart. 6. Stop pump/power source. Disconnect hoses from unit. 7. See Figure 12. The high pressure return coupler (6) must be removed to allow installation of the intensifier into housing. See Figure 11. Insert button head socket screw (2) into housing assembly (1). Lubricate spacers (3) with petroleum jelly and install on each screw (2). Install intensifier in housing (1). Secure intensifier with screws (2) and spacers (3). Tighten screws. Re-install high pressure return coupler (6). 8. Adjust unloading valve to correct setting. See Unloading Valve Relief Setting. TORQUING SEQUENCE Readjust intensifier in vise, maintaining horizontal position, and clamping on motor housing assembly (5), scavenger pump body (11), and/or wobble plate housing (28). Note: Clamping differently than instructed above may cause improper compression of parts and unit failure. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /

23 GREENLEE FAIRMONT Dynapress Intensifier Unloading Valve Relief Setting The unloading valve is preset to the correct relief setting in the factory, and should only need to be reset after snubber assembly is removed, if unit does not function properly, or after disassembly. See Troubleshooting chart before adjusting unloading valve. Correct relief setting for each model is listed in Specifications - Dynapress. 1. For complete hook-up instructions, see Unit/Hose Connections. Connect Dynapress to appropriate remote control and tool, installing an in-line pressure test gauge in the high pressure tool supply line. 2. Connect Dynapress to hydraulic power source. See Unit/Hose Connections. 3. Start Dynapress. The Dynapress has no ON/OFF control, but is actuated by the remote control trigger. Actuate remote control and cycle unit 5-6 times, releasing remote control trigger before pressure builds above 2000 psi. This will help bleed trapped air from the hydraulic system. 4. Actuate and hold remote control trigger. Note pressure reading of pressure test gauge. Pressure should build repeatedly to a specific PSI reading, then drop to almost zero PSI. The consistent upper reading is the unloading valve relief setting. 5. Stop pump/power source. Depressurize hydraulic system. See Figure 11. Remove relief valve cap (38). See Figure 14. To increase relief setting, first make sure that set screw (6) is loose, then turn spring cup retainer (5) clockwise; to decrease setting, turn spring cup retainer counterclockwise. Limit adjustment of unloading valve relief setting to one-half (1/2) turn or less. Then re-check relief pressure setting. A small adjustment can cause a large change in relief setting. Over-tightening may increase relief setting above recommended level. Failure to observe this warning could result in severe injury or death. 6. Tighten hex socket head set screw (6) to secure spring cup retainer. 7. Repeat steps 4 through 6 until correct relief setting is reached. DO NOT exceed recommended relief setting for the Dynapress model being used. MVU Snubber Removal/Installation (not used on 48395) Under certain operating conditions (hydraulic oil temperature and viscosity) the MVU snubber assembly must be removed or installed. Always stop pump/power source before connecting or disconnecting system components. Always depressurize hydraulic system (lowpressure and high-pressure) before disconnnecting unit and/or system components. Do not disconnect system components, lines or fittings while pump/power source and/or if hydraulic fluid is hot. Exposure to hot hydraulic fluid can cause serious burns. Failure to observe these warnings could result in severe injury or death. Conditions Which Can Cause Malfunction of Intensifier During Operation: 1. Low viscosity (thin) hydraulic oil (Example: Mil Spec 5606). 2. Hydraulic oil at relatively high temperatures (above 70 F). Malfunctions During Operation Which Indicates That MVU Snubber Assembly Should Be Removed: 1. The control valve will not automatically return to neutral at the completion of a cycle (crimp, cut, etc.). 2. The tool connected to the intensifier remains in an extended position. 3. The intensifier continues to cycle. 4. The control valve has to be manually returned to neutral. Snubber Removal 1. See Figure 10. Clamp housing, with intensifier inside, in a vise. Remove the male coupler (2), adapter (3), and nipple (4). 2. Remove relief valve cap (5). Remove socket head set screw (6) from unloading valve assembly (7). Remove unloading valve assembly (7), with MVU snubber assembly (8), from the end of the intensifier. Greenlee Textron Inc. / Subsidiary of Textron Inc Boeing Dr., Rockford, IL /