Green Machine- 920 Owners Manual

The Green Machine - 920 Manufactured by: Action Coupling & Equipment, Inc. Key Features Actions Green Machine - 920 Commercial duty Floor model with fork lift slots. Motor: 2 HP single or three phase (please specify, available 220 volt single, 220 & 440 volt 3 phase) Pump: high/low 3,000psi max., low speed 1,800 rpm. High-speed approach, low speed expand for fast cycle & excellent control. Low speed pump for longer life & quiet operation. 10-gallon reservoir with level gauge. Spin on quick-change oil filter. Control: Two way - right hand, left hand. Three way with foot peddle option. Gauge: 5,000psi liquid filled, placed on the top of unit, at 45-degree angle, for easy reading. Cylinder: 4 bore, 20 ton @3,000 lbs of pressure Will accept Akron, Scandia (later models) & Red Head expansion units. Action s expansion units are designed so that the segment holders cannot be over expanded. General specifications for Action s Green Machine 920 24 ½ inch wide 18 ¼ inch deep 46 ½ inch high Weight: 500 lbs Oil reservoir: 10 gallons (use Arco tractor fluid or equivalent) Pump: 3,000psi Motor: 2 HP, 230volt, 1725 rpm Control voltage: 115 volts Cylinder: 4 inch bore Expansion control: right hand/left hand Electrical switching of solenoid valves. Page 1 of 14

Basic Item Description Page 2 of 14

Electrical 230 volts, 1 phase, 10.7 amps standard Your machine is also supplied with a disconnect switch on the left rear. This switch is also suitable for lockout tag-out. Drop should be 14/3 Position Green Machine 4inches from wall for ventilation. Motor -clockwise rotation as peering down on motor. Fig. #3 Switching from 440 or 220 volts If needed, the expanders can be changed from 220 volt-3 phase to 440 volt 3 phase or visa versa, by switching the wires that connect to the motor and the 110-volt transformer. For the motor- rewire the marked wires coming out of the motor junction box as such. 220 volt-3 phase 440 volt-3 phase 4 5 6 4 5 6 7 8 9 7 8 9 1 2 3 1 2 3 To Line To Line For the 110-volt transformer-rewire the incoming leads using the jumpers provided. 220 volt-3 phase 440 volt-3 phase H1 H2 H3 H4 H1 H2 H3 H4 (5 AMP FUSE) (5 AMP FUSE) X1 X2 X1 X2 110 VOLT 110 VOLT Page 3 of 14

To set expansion unit for segment holder protection feature 1) Start Green Machine 2) Move cylinder rod out all the way. Adjust the pressure so that it is as low as possible. The cylinder adapter should be screwed in tight and protruding out of the nosepiece by roughly ¾ inch. If this is not the case you can loosen the retaining ring around the back of the nose piece and screw the nose piece in or out to get your measurement. Than retighten the retaining ring so that the nosepiece does not move on you when screwing in the segment assembly. 3) With the expansion unit assembled, (1 through 2 inch) screw the drawbar adapter into the cylinder adapter tightly. On any drawbars that have a drawbar adapter, we suggest that you leave the drawbar adapter on and unscrew it and the drawbar as an assembly so that it is set-up for the next time you use that size. On the 2-1/2, 3, and 3 x 2-1/2 assemblies, screw the drawbar into the cylinder adapter tightly (make sure tat he adjusting ring is already on the nose piece) 4) Pull the segments and holder toward you on the drawbar as far as they will go. The distance between the front of the nosepiece and the flange behind the thread on the segment holder must be 6 inches (see fig #4 & #6). The hydraulic cylinders have a stroke of roughly six inches, so by adjusting the assembly like such you will get as much rise on the segments as possible, but will not be so short that you are putting pressure between the segment holder and the drawbar. This also assures that the pressure you are reading on the gauge is between the copper ring and the segments. 5) If the measurement is less than 6 inches, adjustment can be made in two different spots. Spot number one is between the drawbar and the drawbar adapter on 1,1 ½, 1 ¾ & 2 inch units. Loosen the setscrew on the drawbar adapter; screw the drawbar out until you get the six inches and than retighten the setscrew on drawbar adapter. By making this adjustment here, you are assuring that the next time you put this unit on its already set. This is essential for easy of operation on the 1 thru 2 inch assemblies, but doesn t work on the sizes without drawbar adapters. So spot number two is on the nosepiece. By loosening the retaining ring at the back of the nose piece and screwing the nosepiece in you can obtain your six inches as well. Always remember to tighten back down the two bolts on the retaining ring so that it does not turn on you when screwing in the segment assembly. If the measurement is over six inches you can also make the measurement change by screwing the nosepiece out. This is done similarly to the above process, with the exception that the nosepiece is screwed out. Having these two spots where adjustments can be made to obtain the six inches might seem rather confusing at first, but once everything is adjusted in setup time from one size to another is greatly reduced. 6) After achieving the six inch spacing, move the drawbar in 2 to 3 inches using the expand button, this is so that the segment holder can be screwed into the nose piece (see fig #5 & #7). Make sure to keep the connection between the segment holder and nosepiece tight. Page 4 of 14

7) Move the drawbar out until it stops using the retract button. Make sure that the copper ring slides over the segments freely. If not it is possible that the unit is the wrong sizes or was not properly setup. Now press and hold the expand button unit the drawbar stops moving in. At this point the segments are as far out as they will travel and the maximum expanded diameter can be measured using a set of calipers and compared to the table below. Size Relaxed Expanded 1" reg 0.890 1.125 1" oversized 0.995 1.270 1-1/2" 1.380 1.855 1-3/4" 1.500 2.040 2" 1.860 2.425 2 X 1-1/2" 1.483 2.293 2-1//2" 2.230 2.850 3" x 2-1/2" 2.520 3.375 3" 2.812 3.406 3-1/2" 3.297 3.900 4" 3.755 4.700 4-1/2" 4.220 5.210 5" 4.800 5.700 6" 5.740 6.680 If the measured diameter is majorily off from the values above, it is highly probable that an error was made in setting up the six-inch rule. If that s the case, repeat the earlier sections. This table also will aid in identifying the segment assemblies on sizes rarely used. When these adjustments are made, it will be impossible to break or expand the segment holder. The cylinder will bottom out at maximum expansion. Action expansion units are designed to give maximum expansion and bottom out at the same time. Most other expansion units will work on the Green Machine, but may not be adjustable to bottom out. The magic number is 6 inches (see fig #4 & #6). As an added safety feature on the Green Machine, when the cylinder is fully retracted (bottomed out) a red light will come on. If during expansion the light comes on: 1) Check that the distance is 6 inches (see fig #4 & #6) 2) Make sure that the expansion unit matches the hose size. Example: 2 ½ inch unit with 3 x 2 ½ inch coupling. 1 ¾ unit with 1 ½ x 2 coupling Page 5 of 14

Suction Expansion Unit Setup - 3 ½, 4, 4 ½, 5 and 6 inch Refer to (fig #8) The larger sizes of expansion units all use the same drawbar (p/n 17040). This drawbar is of significant size and requires that it be screwed directly into the cylinder rod. The segment holder is also the exact same (p/n 17075) for all sizes above 3.5 and thus all procedures are identical for the setup and use of suction expansion units. Typical practice for most companies is to have one drawbar, one adjusting ring and than separate segment/segment holders for each size that they might encounter. 1) Remove the cylinder adapter (C) from the cylinder rod (A) 2) Remove (if applicable) any 2 ½ adjusting collar on thread (B) 3) Screw common 3 ½ to 6 adjusting ring (p/n 17165) onto desired size segment holder (E) 4) Screw drawbar (D) directly into the cylinder rod (A) 5) Push drawbar (D) through segments and segment holder (E) 6) Screw segment holder (E) onto thread (B) Page 6 of 14

920 Green Machine by Ation Coupling & Equipment, Inc. 220 Volt, Single Phase - Wiring Instructions Customer Connection is to take place in the 2 x 4 electrical box on the outside, left, back of the machine. This allows the customer to use a drop cord, EMT conduit or any other means that they wish. Upon cover removal, the installer will notice 4 wires and they are to be wired as such: RED = 110 volt hot leg BLACK = 110 volt hot leg WHITE = Neutral GREEN = Ground The green wire is an actual ground wire connected to the frame of the machine and is to be consider as such. Page 7 of 14

Expansion pressures for Actions Green Machine - 920 The pressures listed below are to be used as a guideline for expanding our couplings. This pressure may not be appropriate for couplings made of other materials or by other manufactures. They may also not be appropriate for other makes of expansion units. 1, 1 ½ inch rack & 1 inch Forestry aluminum 550 to 600 lbs 1 ½ inch SJ & 1 ½ inch Forestry aluminum.600 to 700 lbs 1 ½, 1 ¾, 2 inch DJ & 2 ½ inch SJ aluminum 950 to 1,000 lbs 2 ½ inch DJ aluminum..1,100 to 1,200 lbs 3 inch aluminum.1,200 to 1,300 lbs 3 ½, 4, 4 ½, 5 & 6 inch DJ aluminum. 1,800 to 2,000 lbs 4, 4 ½, 5 & 6 inch SJ aluminum....1,400 to 1,600 lbs 3 inch brass....800 to 850 lbs 4 inch brass. 1,000 to 1,200 lbs All other brass..... 500 to 600 lbs Any brass should not be expanded past the point where it starts to yield. Page 8 of 14

Preventative Maintenance for Green Machine Thank you for your purchase of an Action Coupling Green Machine. Your expander has very little preventative maintenance that is required. We suggest that every 250 hours of use the following checklist be followed, to assure smooth operation. Change Hydraulic Filter Your expander is supplied with a Parker Hydraulic filter. It is recommended that the filter be replaced after the first 50 hours of service and every 250 hours thereafter. Open the cabinet door that is located on the side of the machine. The filter should be noticeable at this time. With the pump off, unscrew the filter with a filter wrench. There might be a small amount of oil that leaks out at this time. On the new filter, smear a light layer of oil on the gasket and then screw into place. Tighten accordingly. Check Hydraulic Oil With the door open you will notice that in the bottom of the cabinet there is a 10-gallon hydraulic tank. There will be a sight gauge, on the side of the tank, with two lines on it. The level of the oil should be between these two lines. If it is not, remove the cap on the top of the tank and fill till the above requirement is met. The oil to be used is a type C-3 hydraulic fluid (or commonly referred to as tractor fluid), which is approximately a grade 30. Clean Oil Cooler On the larger expander, the Green Machine 930, it is necessary to have an oil cooler on the machine. This is essentially a small radiator that disperses the heat in the oil. Dust will be drawn in and will clog the fins on the radiator, so you will need to blow this out with air. Visual Inspection Before closing up the machine, we suggest that you visually verify that there are no leaks or loose fittings. Depending on the age of the unit, this can be a very cost saving inspection. Hydraulic hoses do deteriorate with time, and fittings can vibrate loose. This should also be done on new expanders to verify that there was no damage in transit to your facility. Drawbar Lubrication The drawbar is the tapered bar that is pulled into the machine when expanding. It is vital that this bar be well lubricated, due to the combination of radial forces and the constant sliding of the segments on it. We recommend that a heavy grease be used or a graphite lubricant. It is essential that the grease remains on the drawbar and not be removed after expanding once or twice. That concludes the periodic maintenance that is required on your machine. If you have any problems or questions, please do not hesitate to call. Action Coupling & Equip., Inc.,8248 CR 245, PO Box 99, Holmesville, Oh. 44633, Phone #: 330-279-4242 Page 9 of 14

The following pages include additional drawings to add in the understanding of the six inch rule. The unit pictured is a one inch forestry coupling and although it might not be the size of coupling that you are expanding, the technique is the same for all the sizes of couplings. Page 10 of 14