Greenlee Fairmont RK6040 User manual

INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 4670.0 REV 1 © 2002 Greenlee Textron 4/02
RK6040
60-ton, Single-acting,
Die-type Crimping Tool

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
Table of Contents
Description .....................................................................2
Safety ............................................................................ 2
Purpose of this Manual ..................................................2
Important Safety Information......................................3–4
Identification ................................................................... 5
Specifications .................................................................5
Setup..............................................................................6
Operation .......................................................................7
Maintenance...................................................................7
Periodic Relief Valve Check...........................................7
Illustration and Parts List............................................8–9
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron shall not be liable for damages
resulting from misapplication or misuse of its products.
Dynapress is a registered trademark of Greenlee Textron.
Description
The Fairmont 60-ton, Single-acting, Die-type Crimping
Tool is intended to crimp sleeves and lugs using industry
standard dies. The single-acting ram requires hydraulic
pressure to advance, and uses an internal spring to
return.
This crimping tool requires an external 700 bar
(10,000 psi) hydraulic power source, such as Greenlee
975, 976-22, 980 and 980-22. It may also be powered
using a hydraulic intensifier capable of developing
700 bar (10,000 psi), such as the Fairmont Dynapress®.
Optional accessories include the following hydraulic
hoses with one male and one female coupler:
• 500 5850.9 3 m (10') Conductive
• 500 5851.7 3 m (10') Non-Conductive
• 500 5852.2 7.6 m (25') Non-Conductive
Safety
Safety is essential in the use and maintenance of
Fairmont tools and equipment. This 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 of this Manual
This instruction manual is intended to familiarize
operators and maintenance personnel with the safe
operation and maintenance procedures for the Fairmont
60-ton, Single-acting, Die-type Crimping Tool. This
manual should be kept available to all operating and
maintenance personnel.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge.
KEEPTHIS MANUAL

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
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.
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.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
SAFETY
ALERT
SYMBOL
IMPORTANT SAFETY INFORMATION
Do not use this crimping tool with any hydraulic
hoses or other hydraulic components rated at less
than 700 bar (10,000 psi).
Failure to observe this warning will result in severe
injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
IMPORTANT SAFETY INSTRUCTIONS
• Do not operate crimping tool without dies in place.
Damage to the ram or crimping tool head may
result.
• Do not perform any service or maintenance other
than as described in this manual. Injury or damage
to the tool may result.
Follow the operating instructions and safety
information supplied with the hydraulic power
source.
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.
Use proper die, connector, and wire combinations.
Mismatched components can result in an incomplete
crimp. Failure to complete a crimp can result in
severe injury, death, or fire if a connection separates
or if it has high electrical resistance.
Pinch points:
Keep hands away from closing
dies.
Wear eye protection when using
this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
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.
Electrical shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use only certified
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning can
result in severe injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
2
6
7
Identification—RK6040
1. Die Release Buttons
2. Head Die Retaining Pin
3. Ram Die Retaining Pin
4. Stand
5. Cap Release Lever
6. Lifting Eye
7. Hydraulic Coupling (3/8 threaded)
Specifications
Weight ................................................................................................... 20.2 kg (45 lb)
Width ......................................................................................................152.5 mm (6")
Height...................................................................................................431.8 mm (17")
Stroke (with dies) ..................................................................................37.8 mm (1.5")
Die Type........................................................... Burndy “L” type and Alcoa 6000 series
Crimp Force .......................................................................................530 kN (60 tons)
Power Source Required ............................................................... 700 bar (10,000 psi)
Oil Capacity Required ...................................................................... 312 cc (0.75 pint)
5
1
4
3

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
Setup
Do not operate crimping tool without dies in
place. Damage to the ram or crimping tool head
may result.
Follow the operating instructions and safety
information supplied with the hydraulic power
source.
1. Select the die set that corresponds to the size, type,
and manufacturer of connector to be crimped.
2. Press the release button on the ram and slide one of
the die halves into the jaw. Release the button and
slide the die half until the retainer snaps and locks
the die into place.
Press the die release button on the cap and slide the
other die half in. Release the button and slide the die
until the retainer snaps and locks into place.
3. Connect the hydraulic hose from the power source
to the tool.
4. In cold weather, allow the power source to run
(idle) for a few minutes to warm the hydraulic fluid.
Actuating the tool intermittently will reduce the time
required to warm the fluid to an efficient operating
temperature.
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.
Use proper die, connector, and wire combinations.
Mismatched components can result in an incomplete
crimp. Failure to complete a crimp can result in
severe injury, death, or fire if a connection separates
or if it has high electrical resistance.
Wear eye protection when using this
tool.
Failure to wear eye protection can
result in serious eye injury from flying
debris or hydraulic oil.
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.
Do not use this crimping tool with any hydraulic
hoses or other hydraulic components rated at less
than 700 bar (10,000 psi).
Failure to observe this warning will result in severe
injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
Operation
Electrical shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use only certified
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning can
result in severe injury or death.
Pinch points:
Keep hands away from closing dies.
Note: Consult the connector manufacturer’s instructions
for the proper crimping procedure and proper die(s), etc.
1. Prepare the cable by stripping off the appropriate
amount of insulation.
2. Select a connector that corresponds to the conduc-
tor and the application.
3. Insert the conductor into the connector. Position the
connector between the crimping dies.
4. Activate the hydraulic power source until the ram
has advanced and the crimp is completed.
Note: To assure a complete crimp, verify that the
power source has reached 700 bar (10,000 psi).
Refer to “Periodic Relief Valve Check” in this
manual.
5. Stop the power source and allow the ram to retract.
Maintenance
• Keep the tool clean. Use the tool with care to keep dirt
and grit out of the hydraulic system. Contamination is
the most common cause of failure for hydraulic tools.
• Store the tool in its original case with the ram fully
retracted.
• Occasionally lubricate the die release button
assemblies. A molybdenum disulfide grease is recom-
mended.
• Inspect the hydraulic hoses periodically.
• Periodically verify that the power source reaches
700 bar (10,000 psi). Refer to “Periodic Relief Valve
Check” in this manual.
Relief valve adjustments must be performed
according to the instructions provided with the
hydraulic power source.
Periodically verify that your hydraulic power source
is supplying between 9600 psi and 10,400 psi
(662 bar and 717 bar).
Use a test-quality pressure gauge on the supply line
from the hydraulic power source.
1. Refer to the instructions supplied with the pressure
gauge.
2. Stop the flow of hydraulic oil from the power source.
3. Connect the pressure gauge to the supply line of the
power source.
4. Install the set of test dies into the crimping tool.
5. Activate the power source until the ram has
advanced and the power source reaches relief
pressure. The pressure gauge should read between
9600 psi and 10,400 psi (662 bar and 717 bar) .
6. Release the pressure by stopping flow from your
power source. The ram will retract.
If crimp pressures are low, the hydraulic power source
relief valve may need adjustment.
Periodic ReliefValve Check

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
Illustration
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31
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14
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50
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48

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
RK6040 60-ton, Single-acting, Die-type CrimpingTool
Parts List—RK6040
Key Part No. Description Qty.
1 501 0566.3 Stand ................................................................................................. 1
2 501 0567.1 Lifting ring.......................................................................................... 1
3 501 0568.0 Screw ................................................................................................ 2
4 501 0569.8 Block, hook guide .............................................................................. 2
5 501 0570.1 Pin ..................................................................................................... 4
6 501 0571.0 Screw ................................................................................................ 2
7 501 0572.8 Block, oil feed .................................................................................... 1
8* 501 0573.6 O-ring ................................................................................................ 1
9 501 0574.4 Spring ................................................................................................ 1
10 501 0576.0 Holder, ball ........................................................................................ 1
11* 501 0577.9 Ball .................................................................................................... 1
12 501 0578.7 Screw, anchor spring......................................................................... 1
13* 501 0579.5 Backup ring ....................................................................................... 2
14* 501 0580.9 O-ring ................................................................................................ 2
15 501 0581.7 Head, cylinder ................................................................................... 1
16 501 0584.1 Block, handle holder.......................................................................... 2
17 501 0585.0 Pin ..................................................................................................... 2
18 501 0586.8 Handle ............................................................................................... 1
19 501 0587.6 Driver, center spring .......................................................................... 1
20* 501 0588.4 O-ring ................................................................................................ 1
21* 501 0589.2 Backup ring ....................................................................................... 1
22 501 0590.6 Screw ................................................................................................ 1
23 501 0591.4 Washer .............................................................................................. 1
24 501 0592.2 Ram................................................................................................... 1
25 501 0593.0 Guide, ram......................................................................................... 2
26 501 0594.9 Pin ..................................................................................................... 2
27 501 0595.7 Screw, anchor spring......................................................................... 1
28 501 0596.5 Pin ..................................................................................................... 2
29 501 0597.3 Spring ................................................................................................ 2
30 501 0598.1 Pin, die .............................................................................................. 2
31 501 0599.0 Pin, retainer ....................................................................................... 2
32 501 0600.7 Screw ................................................................................................ 2
33 501 0601.5 Retainer............................................................................................. 2
34 501 0602.3 Retainer, holder................................................................................. 1
35 501 0603.1 Cap.................................................................................................... 1
36 501 0619.8 Screw ................................................................................................ 4
37 501 0605.8 Handle, head cap .............................................................................. 1
38 501 0607.4 Pin ..................................................................................................... 2
39 501 0608.2 Spring ................................................................................................ 1
40 501 0609.0 Pin ..................................................................................................... 1
41 501 0610.4 Screw ................................................................................................ 2
42 501 0611.2 Switch, release .................................................................................. 1
43 501 0612.0 Coupler, threaded male, 3/8" ............................................................ 1
44 501 0613.9 Cap, coupler with lanyard.................................................................. 1
45 501 0614.7 Washer .............................................................................................. 2
46 501 0615.5 Screw ................................................................................................ 2
47 501 0616.3 Wire, connect .................................................................................... 1
48 501 0617.1 Decal, identification ........................................................................... 2
49 501 0618.0 Box, metal ......................................................................................... 1
50 500 6214.0 Decal, pinch hazard........................................................................... 1
51 500 1695.4 Decal, warning................................................................................... 1
52 F011604 Nipple, 3/8 NPTF............................................................................... 1
500 1743.8 Seal kit (includes items marked with an asterisk)

Printed in the USA
Greenlee Textron / Subsidiary of Textron Inc.
4455 Boeing Drive, Rockford, IL 61109-2988 USA
Customer Service (International): 815/397-7070 • Fax: [phone]
Customer Service (North America): 800/435-0786 • USA Fax: [phone]
Canada Fax: [phone]
www.greenlee.textron.com