Greenlee UAP32GL GATOR Instruction Manual

INSTRUCTION MANUAL
UAP32GL BATTERY-POWERED
PRESSING TOOL
WITH 2-SPEED RAM
999 3728.0 © 2001 Greenlee Textron IM 1457 REV 1 7/01
TM
GATOR
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
GATOR™ Battery-powered Pressing Tool
Table of Contents
Description ..................................................................... 2
Purpose..........................................................................2
Important Safety Instructions......................................3-4
Identification................................................................... 5
Location of Decals .........................................................6
Specifications................................................................. 6
Operation ....................................................................7-9
Maintenance ................................................................10
Troubleshooting ........................................................... 11
Disassembly.................................................................12
Reassembly .................................................................13
Service ......................................................................... 14
Exploded Views ......................................................15-17
Parts List .................................................................18-20
Safety
Safety is essential in the use and maintenance of Greenlee tools and equipment. This instruction manual and any markings on the tool provide information for avoiding hazards and unsafe practices related to the use of this tool. Observe all of the safety information provided.
Purpose
This instruction manual is intended to familiarize personnel with the safe operation and maintenance procedures for the Gator™ UAP32GL Battery-powered Pressing Tool.
Keep this manual available to all personnel. Replacement manuals are available upon request
at no charge.
Description
The UAP32GL Battery-powered Pressing Tool is a hand-held, self-contained tool intended to press compression pipe fittings.
Greenlee Textron / Subsidiary of Textron Inc.
KEEP THIS MANUAL
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
GATOR Battery-powered Pressing Tool
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, defined below, indicates the severity of the hazard. The message after the signal word provides information for prevent­ing or avoiding the hazard.
Electrical Shock Hazard: This tool is not insulated. When
using this unit near energized electrical lines use proper personal protective equipment.
Failure to observe this warning could result in severe injury or death.
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 will result in severe injury or death.
Skin Injection Hazard: Do not use fingers or hands to
check for oil leaks. High pressure oil easily punctures skin causing serious injury, gangrene or death. If injured seek medical help imme­diately to remove oil.
Do not use solvents or flammable cleaners to clean the tool body. Solvents could ignite causing serious injury or property damage.
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
GATOR Battery-powered Pressing Tool
IMPORTANT SAFETY INFORMATION
Inspect tool and dies before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel with sufficient force to cause severe injury or death.
Keep hands and fingers away from closing dies.
Lock trigger when not in use.
Do not dispose of batteries in a fire. They will vent vapors and may explode.
Failure to observe this warning may result in injury from inhalation of vapors or burns from flying debris.
Wear eye protection when using this tool.
Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.
Do not operate tool without dies. Damage to the ram or tool head may result.
This tool is not designed for continuous use. After 30 – 40 pressing cycles, allow the tool to cool for 15 minutes.
Do not place tool in a vise. The tool is designed for hand-held operation.
Keep water from inside of tool. Water inside tool or battery may damage internal circuitry.
Use this tool for manufacturers intended purpose only. Use other than that which is described in this manual can result in injury or property damage.
Failure to observe these precautions can result in injury and property damage.
Do not immerse batteries in water or any conduc­tive liquid. If batteries are immersed, contact your service center for proper handling.
Never short between the battery terminals.
Use only the manufacturer-supplied charger rated
for 12 volt nickel cadmium batteries.
Do not disassemble or perform modifications to the battery. (There are no user serviceable components in the battery.) Failure to comply may result in injury or damage to the battery from rapid discharge of battery energy.
Do not place battery into pocket or toolbox with conductive objects (coins, keys, tools, etc.). Failure to observe this precaution could result in burn injury from rapid discharge of battery energy.
A battery placed on its nose on damp ground or grass may be damaged by an electrical short.
Do not store batteries above 60°C/140°F for extended periods. Battery damage may result.
Failure to observe these warnings may result in personal injury or damage to the battery from rapid discharge of battery energy.
Greenlee Textron / Subsidiary of Textron Inc.
Do not perform any service or maintenance other than as described in this manual. Injury or damage to the tool may result.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Identification
GATOR Battery-powered Pressing Tool
8 & 9
(under cover)
7
6
5
LOCK
UNLOCK
4
1. Housing
2. Retract Button
3. Battery
4. Hand Guard
5. Trigger Lock Switch
6. Trigger
7. Battery Load Display
8. Oil Reservoir
9. Oil Plug
1
2
3
Greenlee Textron / Subsidiary of Textron Inc.
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Specifications
Weight (with battery)................................................................... 10.8 lbs. (4.9 kg)
Overall Length ...........................................................................12-3/8" (31.4 cm)
Width.................................................................................................... 3" (76 mm)
Height......................................................................................... 11-3/4" (29.8 cm)
Maximum Force .............................................................................. 3 tons (32 kN)
Motor......................................................... Direct-Current Permanent Field Motor
Motor Voltage............................................................................................ 12 VDC
Charging Voltage ........................................................................................... 12 V
Charging Time ............................................................................................ 1 Hour
Pressing Time ................................................................................ 4 to 7 seconds
Pressing Performance ................................................. approximately 120/charge
Hydraulic Oil..........................................................1 pint (50 ml) Shell Tellus T 15
Pressing Head ...............................................................................................Steel
Sound Level .......................................................................... 75 dB (A) at 1 meter
Vibration............................................................................................... <2.5 m/s2s
GATOR Battery-powered Pressing Tool
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Operation
GATOR Battery-powered Pressing Tool
Electrical Shock Hazard: This tool is not insulated. When
using this unit near energized electrical lines use proper personal protective equipment.
Failure to observe this warning could result in severe injury or death.
Keep hands and fingers away from closing dies.
Lock trigger when not in use.
Wear eye protection when using this tool.
Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.
Do not operate tool without dies. Damage to the ram or tool head may result.
This tool is not designed for continuous use. After 30 – 40 pressing cycles, allow the tool to cool for 15 minutes.
Do not place tool in a vise. The tool is designed for hand-held operation.
Keep water from inside of tool. Water inside tool or battery may damage internal circuitry.
Use this tool for manufacturers intended purpose only. Use other than that which is described in this manual can result in injury or property damage.
Failure to observe these precautions can result in injury and property damage.
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
GATOR Battery-powered Pressing Tool
Operation (contd)
Charging the Battery
Read the instructions supplied with the charger for explanation of proper use.
Battery Condition
Battery Load Display Battery Condition
Momentary illumination at beginning of pressing cycle Normal or operating charge level Flickering at point of maximum pressing force Normal or operating charge level Flickering during entire pressing cycle Low charge level Constant when operating without a load Low charge level
Greenlee Textron / Subsidiary of Textron Inc.
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GATOR Battery-powered Pressing Tool
Operation (contd)
Installing Pressing Dies
1. Select the proper die according to the connector manufacturers instructions.
2. Press the ram retract button.
3. Push the trigger lock to the locked position.
4. Open the pressing head and slide die into pressing head until it snaps into place. Install the second die.
Pull trigger to crimp
Dies are purchased from connector manufacturer.
Pressing Fittings
1. Prepare the pipe and fitting according to the con­nector manufacturers instructions.
2. Open jaws and place pressing dies around the fitting.
3. Unlock trigger.
4. Squeeze trigger to advance pressing jaws.
Note: To make sure that a good pressing cycle is
completed, check to see if jaws touch before max pressure is achieved.
5. Ram will return automatically after the pressing cycle is completed. A pop sound will be heard at the end of a cycle.
Note: The pressing cycle can be stopped at any
time by releasing trigger. The ram can be returned by pressing the retract button.
Push trigger lock down to release
Push to retract ram
Greenlee Textron / Subsidiary of Textron Inc.
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GATOR Battery-powered Pressing Tool
Maintenance
Each Operating Day
Before Use:
1. Inspect dies for defects, such as cracks, gouges or chips.
2. Inspect the tool for damage or leaks. If damage is detected, return the tool to an authorized Greenlee service center.
Monthly
1. Thoroughly clean all surfaces.
2. Check the oil level.
3. Oil the bolt joints.
Annually or After 10,000 Pressing Cycles
1. Change the hydraulic oil.
2. Return the tool to an authorized Greenlee service center for inspection.
High Pressure Hazard: Do not use fingers or hands to
check for oil leaks. High pressure oil easily punctures skin causing serious injury, gangrene or death. If injured seek medical help immedi­ately to remove oil.
After Use:
1. Wipe clean and dry all exposed surfaces.
Note: Use a slightly damp cloth and a mild
detergent to clean the cutter body. Solvents can damage the cutter body and may ignite.
Do not use solvents or flammable cleaners to clean tool body. Sol­vents could ignite causing serious injury or property damage.
2. Fully retract and lock trigger. Place the tool in the carrying case. Store in a cool, dry place.
3. Fully discharged batteries should be recharged so that they are ready for use. (See battery charger instructions.)
General
Store the tool in the carrying case when it is not in use.
Checking the Oil Level
1. Remove the two screws holding the tank housing cover.
2. Remove the tank housing cover.
3. Point the head towards the ground and remove the oil plug. Refill reservoir if necessary.
4. Replace the oil plug and the tank housing cover.
Recommended Hydraulic Oils
AVIA HVI 15 Shell Tellus T 15 MOBIL DTE 11 NUTO H 15
Greenlee Textron / Subsidiary of Textron Inc.
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Troubleshooting
GATOR Battery-powered Pressing Tool
BEFORE YOU BEGIN
1. Make sure that the battery is charged. Recheck the battery after several minutes to make sure the battery is holding its charge.
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.
of tool. Tool battery contacts damaged. Reform contacts. Tool components worn or Return tool to an authorized
damaged. Greenlee service center.
Dies stop during operation. Oil level is low. Check oil level. Refill reservoir.
Air in hydraulic system. Pull trigger and hold retract button
2. Use a NONFLAMMABLE contact cleaner or pencil eraser to clean the electrical contacts on the battery and tool.
3. Reinstall battery and check the tool again.
simultaneously. Hold for approximately 10 seconds.
Battery load display flashes Battery charge low. Charge or replace battery. constantly.
Tool loses oil. Damaged internal seal. Return tool to an authorized Greenlee
service center.
Oil plug not installed properly. Refill reservoir and replace plug.
Greenlee Textron / Subsidiary of Textron Inc.
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Disassembly
GATOR Battery-Powered Pressing Tool
1. Remove battery.
2. Loosen two screws (106).
3. Unscrew and remove pressing head assembly.
4. Remove piston (114). Replace the piston O-ring (115) and piston backup ring (116).
5. Unscrew two tank cover screws (207) and remove tank cover.
6. Remove the hydraulic reservoir plug (17) and drain hydraulic fluid.
7. Reinstall plug.
8. Remove the remaining housing screws (208, 209, 210, 202).
9. Remove left housing half.
10. Remove switch cover (205) and trigger lock (204).
11. Lift pump/motor assembly and circuit card from right housing half. Lift LED from its bushing (206).
12. Slide a plastic bag over the circuit card and elec­tronic subassemblies. Tape the bag shut to protect the subassemblies from hydraulic oil and other contamination.
13. Unscrew shoulder bolt (16) and remove release lever (19).
14. Remove hex head cap screws (7) and separate the gear housing/motor subassembly from pump housing.
15. Use a hooked tool to remove the reservoir O-ring (40). Gently tug it over the reservoir.
16. Remove the reservoir (18).
17. Remove pump piston (53). Replace the O-ring (51).
18. Remove screw plug (44), spring (46), valve stem (47), pump piston (48) and sealing washer (45).
19. Use a marker or piece of tape to mark the side of the relief (11) that is facing up. This mark or piece of tape will later be used when installing the unloading valve subassembly. Remove unloading valve subassembly by unscrewing the plug (11).
20. Remove feeder tube subassembly by unscrewing feeder tube (37). Replace the oil filters (36). Re­move magnet (38) and clean off metal chips.
21. Remove piston (53).
Motor/Gearbox/Bearing Disassembly
22. Remove tamper-proof paper seal (56).
23. Remove two screws (58). Remove end cap (57).
24. Apply pressure evenly at three points around the ball bearing (54) and gently pry the bearing up to remove it.
25. Remove eccentric (55), grooved ball bearing (32), and snap ring (31) subassembly from shaft.
26. Remove four screws (30). Remove mounting block (8) from gear housing (29).
27. Use a snap-ring removal tool to remove the snap ring (31).
28. Unscrew four bolts (not numbered) from the gear housing (29). Separate gear housing from spacer (not numbered). Unscrew two fillister head screws (28) to separate spacer from motor (25).
Greenlee Textron / Subsidiary of Textron Inc.
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Reassembly
GATOR Battery-Powered Pressing Tool
Motor/Gearbox/Bearing Reassembly
1. Install two fillister head screws (28) into spacer (not numbered) and motor (25). Tighten screws.
2. Install four screws (not numbered) into gear housing (29). Tighten screws.
3. Install four screws (30) into mounting block (8) and gear housing (29). Tighten screws.
4. Replace grooved ball bearing (32) and snap ring (31).
5. Replace eccentric (55). Use a fiber mallet to tap eccentric onto shaft. Replace ball bearing (54).
6. Align end cap (57). Use a fiber mallet to tap cover until it is flush on mounting block (8). Install two screws (58).
7. Align gear housing/motor subassembly so that the pump piston (53) extends through the mounting block (8) and makes contact with the grooved bearing (32). Locate and start the screws (7) through the mounting block and into the pump housing. Tighten the screws.
8. Install release lever (19) so that the forked end engages the needle valve subassembly between the pressure relief (11) and the support ring (12). Install screw (16).
Pump Subassembly
9. Insert pump piston (53) into pump housing.
10. Insert seal (4) and unloading valve subassembly into pump housing. Grasp needle valve subassem­bly by the plug (11) and twist it several turns clock­wise. Stop when the mark or piece of tape (see Step 19 under Disassembly) is facing the screw hole.
11. Assemble pump piston (48), valve stem (47), spring (46) and screw plug (44). Be sure to replace sealing washer (45).
12. Insert threaded bushing (36,37,38). Screw in until snug.
13. Install reservoir (18) so that the flat side faces the same direction as the pump piston. Slip the O-ring (40) over the reservoir. Using a hooked tool, care­fully slip the O-ring over the lip of the pump housing.
14. Insert the plug (17) into the reservoir.
Miscellaneous Components Reassembly
15. Remove the protective plastic bag from the elec­tronics subassembly. Insert he LED into the LED bushing (206).
16. Lay the gear housing/motor subassembly into the right half of the housing. Insert the circuit board into the circuit board slot, so that the wires and chip face in the direction of the trigger.
17. Lay the wires into case. Be sure that the wires will not be pinched.
18. Guide the wires for the battery clip so the battery wires lay on top of the electronics box; install the battery clip so the red wire is upward.
19. Install the switch cover (205) and trigger lock (204). Depress and release the trigger and slide the trigger lock to be sure that they operate freely.
20. Locate the right housing half on top of the left housing half. Check for pinched wires.
21. Install the housing screws (202,208,209,210).
Note: Handle screw (202) must engage the nut
(203).
22. Install the piston (114) and spring assembly.
23.
Replace the front head assembly. Twist the pressing head base (105) until it stops; back off 3/4 of a turn and tighten the screws (106). Be sure that the tool head assembly rotates freely approximately 350°.
24. Clamp the tool head assembly into a vise with the reservoir plug facing upward. Remove the fill plug (17) and fill the reservoir with hydraulic oil.
25. Install the battery.
26. Squeeze the trigger while depressing the release lever for 45-60 seconds. Fill the reservoir with hydraulic oil. Replace the fill plug (17). This might require several attempts to bleed all of the air from the system.
27. Replace the tank cover and tank cover screws (207).
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
GATOR Battery-Powered Pressing Tool
Service
Should your battery-powered tool require service, return it to an authorized Greenlee service center. Customer Center and Field Service: 800/435-0786 Fax (24 Hour) Customer Center: 800/451-2632 or 815/397-1865
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Exploded View
GATOR Battery-Powered Pressing Tool
207
208
215
200
208
210
209
115
116
212
214
200
208
205
204
206
203
202
200
114
113
112
111
110
109
108
213
107
106
104
102
103
101
Greenlee Textron / Subsidiary of Textron Inc.
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100
105
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Exploded View
GATOR Battery-Powered Pressing Tool
17
18
22
40
24
15
25
28
29
16
61
19
13
12
11
9
10
2
20
21
7
31
23
6
Torque to
75 foot-pounds
44
45
46
38
36
37
47
39
48
5
4
51
53
1
50
49
33
62
34
7
8
30
26
27
32
55
54
57
58
56
Greenlee Textron / Subsidiary of Textron Inc.
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4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Exploded View
GATOR Battery-Powered Pressing Tool
117
118
119
120
121
122
123
Greenlee Textron / Subsidiary of Textron Inc.
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Parts List
GATOR Battery-Powered Pressing Tool
KEY PART NO. DESCRIPTION QTY.
1 501 0241.9 Pump Housing ................................................... 1
2 500 5864.9 Plunger............................................................... 1
4 500 5862.2 Seal ....................................................................1
5 500 5863.0 Valve Seat..........................................................1
6 500 5877.0 Needle Valve......................................................1
7 500 8403.8 Screw, Pan Head ...............................................2
8 500 8402.0 Mounting Block .................................................. 1
9 500 5869.0 O-Ring................................................................ 1
10 500 5894.0 Spring................................................................. 1
11 500 5871.1 Pressure Relief ..................................................1
12 500 5875.4 Support Ring ...................................................... 1
13 500 5876.2 Retaining Ring ................................................... 1
15 500 4134.7 O-Ring Needle Valve .........................................1
16 500 4203.3 Screw Flat Head M4 x6 .....................................1
17 500 4122.3 Reservoir Plug ................................................... 1
18 500 5861.4 Hydraulic Reservoir............................................1
19 500 5879.7 Release Lever....................................................1
20 500 4125.8 Relief Lever Spring ............................................1
21 500 5872.0 Screw .................................................................1
22 500 4113.4 Spacer................................................................ 1
23 500 4137.1 Capacitor............................................................3
24 500 4136.3 Ground Strap ..................................................... 1
25 500 4132.0 Motor ..................................................................1
26 500 3633.5 Pin, 4 x 16 .......................................................... 1
27 500 4128.2 Battery Clip ........................................................ 1
28 500 6772.9 Screw, M4 x 10 ..................................................2
29 500 7358.3 Gearbox .............................................................1
30 500 4157.6 Screw, Flat Head M3 x6 .................................... 4
31 500 4151.7 Retaining Ring ................................................... 1
32 500 4139.8 Bearing, Grooved Ball........................................1
33 500 4126.6 Switch.................................................................1
34 500 4127.4 Battery Contacts ................................................1
36 500 5880.0 Filter ...................................................................1
37 500 5882.7 Filter Adapter ..................................................... 1
38 500 5898.3 Magnet ...............................................................1
39 500 5885.1 Threaded Bushing..............................................1
40 500 5886.0 O-Ring................................................................ 1
44 500 5896.7 Screw Plug.........................................................1
45 500 5888.6 Sealing Washer..................................................1
46 500 5889.4 Spring................................................................. 1
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Parts List (contd)
KEY PART NO. DESCRIPTION QTY.
47 500 5890.8 Valve Stem.........................................................1
48 500 5891.6 Pump Piston.......................................................1
49 500 4144.4 Threaded Bushing..............................................1
50 500 4143.6 O-Ring................................................................ 1
51 500 5897.5 O-Ring................................................................ 1
53 500 5892.4 Pump Piston.......................................................1
54 500 4138.0 Ball Bearing........................................................1
55 500 4123.1 Eccentric ............................................................1
56 500 4153.3 Seal ....................................................................1
57 500 4108.8 End Cap .............................................................1
58 500 4155.0 Screw, Flat Head, M3 x 10 ................................ 2
61 500 4922.4 Lock Washer ......................................................1
62 500 5901.7 C-Clip .................................................................1
100 500 7338.9 Pressing Jaw Ass’y (contains #117-123)................2
101 500 7339.7 Pin ......................................................................2
102 500 7341.9 Pivot Pin .............................................................2
103 500 7342.7 Retaining Ring ...................................................4
104 500 7343.5 Pin ......................................................................2
105 500 7344.3 Bottom Yoke ...................................................... 1
106 500 4168.1 Screw, M3 x 6 ....................................................2
107 500 7346.0 Pivot Roller.........................................................2
108 500 7347.8 Roller Holder ......................................................1
109 500 7348.6 Retaining Ring ...................................................1
110 500 7349.4 Stop Disc............................................................1
111 500 7351.6 Spring................................................................. 1
112 500 7352.4 Comp. Spring .....................................................1
113 500 7353.2 Comp. Spring .....................................................1
114 500 7354.0 Piston .................................................................1
115 500 4192.4 O-Ring................................................................1
116 500 4194.0 Backup Ring.......................................................1
117 500 7332.0 Retaining Ring ...................................................1
118 500 4396.0 Compression Spring ..........................................1
119 500 4385.4 Die Retainer .......................................................1
120 500 7333.8 Pressing Jaw......................................................1
121 500 7334.6 Release Lever.................................................... 1
122 500 7336.2 C-Clip .................................................................1
123 500 7337.0 Release Pin........................................................1
GATOR Battery-Powered Pressing Tool
Greenlee Textron / Subsidiary of Textron Inc.
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Parts List (contd)
200 500 7183.1 Housing Kit, Black.............................................. 1
202 500 4220.3 Screw .................................................................1
203 500 4221.1 Nut......................................................................1
204 500 7364.8 Lockout...............................................................1
205 500 7373.7 Switch Cover ......................................................1
206 500 4241.6 LED Bushing ......................................................1
207 500 4236.0 Screw, 3.9 x 16MM ............................................2
208 500 4207.6 Screw, 3.9 x 19MM ............................................4
209 500 4209.2 Screw, 3.9 x 25MM ............................................2
210 500 4208.4 Screw, 3.9 x 38MM ............................................4
212 500 7374.5 Circuit Board ......................................................1
213 500 6214.0 Decal, Pinch Hazard ..........................................1
214 500 7184.0 Decal, Warning .................................................. 1
215 500 7188.2 Decal, Identification............................................1
500 5904.1 Seal Kit (contains 4,9,13,14,38,42,47,48,115,116) 500 7381.8 Unloading Valve Assy (contains 2,4-6,9-13,15) 500 7182.3 Blue Steel Case w/inserts
500 2999.1 12V Battery 500 3046.9 12V Charger 110V AC 500 3047.7 12V Charger 220V AC 500 3048.5 12V Charger 12V DC
Greenlee Textron / Subsidiary of Textron Inc.
4455 Boeing Drive, Rockford, IL 61109-2988 USA
Customer Service (International): 815/397-7070 Fax: 815/397-9247
Customer Service (North America): 800/435-0786 Fax: 800/451-2632, 815/397-1865
Canada Fax: 800/524-2853
Printed in the U.S.A.
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