Greenlee RK12ID User manual

INSTRUCTION MANUAL
RK12ID
Remote Dieless
Crimping Tool
52065531 © 2013 Greenlee Textron Inc. 7/13
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
Serial Number

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
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 of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee Utility tool:
RK12ID Remote Dieless Crimping Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge at www.greenlee.com.
All specications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Blackburn is a registered trademark of Thomas & Betts.
KEEP THIS MANUAL
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information ..................................... 3-4
Identication.................................................................. 5
Specications................................................................ 5
Operation.................................................................... 6-7
cUL and UL Classied Crimps ...................................... 8
Connector Table......................................................... 8
Maintenance............................................................. 9-10
Schedule.................................................................... 9
Periodic Pressure Relief Valve Check................... 9-10
Verify Crimping Distance ......................................... 10
Illustration and Parts List............................................. 11
Description
The RK12ID Remote Dieless Crimping Tool is a dieless
crimping tool intended to crimp aluminum and copper
connectors onto electrical cable.
The RK12ID is to be coupled to any Greenlee or
Greenlee Utility hydraulic pump capable of developing
10,000 psi (700 bar). Suggested pumps include:
Pump Type Model Number
Battery............................................................... EHP700
Hand Pump ...............................................................755
Electric Pump (120 Volt Models) ...............................975
980
Electric Pump (220 Volt Models) ......................... 976-22
980-22
Greenlee Utility Intensier................................. H6710B*
H6710B1*
H6710B4*
* Requires PVA0021 Control Valve

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning could
result in severe injury or death.
Electric shock hazard:
This tool is not insulated. When using
this unit on or near energized electri-
cal lines, use proper personal protec-
tive equipment.
Failure to observe this warning could
result in severe injury or death.
Wear eye protection when operating
this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Skin injection hazard:
• Hand-tighten all couplers com-
pletely before operating the pump.
Do not use tools.
• Do not use hands to check for
leaks.
• Do not hold the hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punctures
skin causing serious injury, gan-
grene or death. If you are injured by
escaping oil, seek medical attention
immediately.

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
IMPORTANT SAFETY INFORMATION
An incomplete crimp can cause a re.
• Use proper connector and cable combinations.
Improper combinations can result in an incomplete
crimp.
• Crimp until the pump has reached relief pressure. If
you do not achieve relief pressure you will have an
incomplete crimp.
Failure to observe these warnings could result in
severe injury or death.
Inspect tool before use. Replace any worn or
damaged parts. A damaged or improperly assembled
tool can break and strike nearby personnel.
Failure to observe this warning could result in severe
injury or death.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.
Follow the instructions and safety information sup-
plied with the pump.
Failure to observe this warning could result in severe
injury or death.
Use only Greenlee supplied hoses and couplers.
Other manufacturers’ components may fail.
Failure to observe this warning could result in severe
injury or death.
Do not operate the tool without a connector in place.
Damage to the ram or crimping tool head can result.
Failure to observe this precaution may result in injury
and property damage.
Note: Keep all decals clean and legible, and replace
when necessary.

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Specifications
Crimping Tool
Length ............................................................................................12.5" (317.5 mm)
Width................................................................................................2.87" (72.9 mm)
Height.............................................................................................4.26" (108.2 mm)
Mass/Weight ......................................................................................9.75 lb (4.4 kg)
Crimping Capacities
Crimping Range
Aluminum............................................................................ 6 AWG to 1000 kcmil
Copper................................................................................ 4 AWG to 1000 kcmil
Crimping Force............................................................................... 12 tons (106 kN)
3
2
4
1
1. Crimping head
2. Latch
3. Indenter
4. Coupler

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Operation
Electric shock hazard:
This tool is not insulated. When using
this unit on or near energized electri-
cal lines, use proper personal protec-
tive equipment.
Failure to observe this warning could
result in severe injury or death.
Wear eye protection when operating
this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Skin injection hazard:
• Hand-tighten all couplers com-
pletely before operating the pump.
Do not use tools.
• Do not use hands to check for
leaks.
• Do not hold the hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punctures
skin causing serious injury, gan-
grene or death. If you are injured by
escaping oil, seek medical attention
immediately.
An incomplete crimp can cause a re.
• Use proper connector and cable combinations.
Improper combinations can result in an incomplete
crimp.
• Crimp until the pump has reached relief pressure.
Ifyou do not achieve relief pressure you will have an
incomplete crimp.
Failure to observe these warnings could result in
severe injury or death.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.
Follow the instructions and safety information sup-
plied with the pump.
Failure to observe this warning could result in severe
injury or death.

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Operation (cont’d)
Preparation
For a cUL or UL classied crimp, refer to the
“Connector Table” in this instruction manual.
1. Select a proper size and type of connector to
correspond with the wire or cable.
2. Strip the cable to an appropriate length. Follow the
connector manufacturer’s instructions.
Note: Apply an oxide inhibitor, if required.
Refer to the connector manufacturer’s instructions.
Crimping
1. Insert the cable fully into the connector.
2. Place the connector into the V of the crimping head,
as shown below.
Connector
3. If open, close the crimping head. Make sure the
head and latch are fully engaged.
4. For a cUL or UL classied crimp, complete the
number of crimps specied in the “Connector Table”
in this manual.
5. For a single crimp, position the connector so the
crimp will be located at the center of the barrel.
For a double crimp, position the connector so two
crimps will be evenly spaced between the connec-
tor marks.
6. Activate the hydraulic power source until the ram
has advanced and the crimp is completed.
Note: To ensure a complete crimp, verify that the
power source has reached 10,000psi (700bar).
Refer to the “Periodic Relief Valve Check” in this
manual.
7. Stop the power source and allow the ram to retract.
8. Lift the latch to open the crimping head and remove
the connector.
Note: After completing the last crimp on an alumi-
num connector, wipe off the excess oxide inhibitor.
An incomplete crimp can cause a re.
Use proper die, connector, and cable combinations.
Improper combinations can result in an incomplete
crimp.
Failure to observe these warnings could result in
severe injury or death.

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
cUL and UL Classified Crimps
Crimps made with the Greenlee Utility RK12ID Remote
Dieless Crimping Tool are cUL and UL classied on
standard concentric, compressed, or compact stranded
copper and aluminum cable with the connectors listed
here. Refer to the “Connector Table” for the brand names
and model numbers of appropriate connectors and the
number of crimps required.
Connector Table
(NOT for use with flex, navy or welding wire)
Copper Connector Type Anderson Blackburn®Burndy Ilsco Panduit T & B Penn-
Union Tyco (AMP)
Copper Splices VHSS
VHS
CSP
CU
YS-L
YS
CT
CTL
SCSS
SCS
SCL, SCH
54506 to 54528
54806 to 54828
BCU
BBCU —
Copper Lugs VHCS
VHCL
CTL
CTL-L
LCN
YA, YA-L, YA-2L
YA-2LN, YA-2N
YA-L-TC, YA-L-2TC
YA-2TC, YAZ
YAZ-2N, YAZ-2TC
CLN, CLW, CSW
CRA, CRB, CRC
CRA-L, CRB-L
CRA-2L
CRB-2L
CRC-2L
LCAS
LCA
LCB
LCD, LCC
LCAN
54106 to 54128
54206 to 54228
54906BE to
54928BE
54854BE to
54882BE
BLU
BBLU
1099898-2 to
1-1099898-5
1099899-2 to
1-1099899-9
1099939-1 to
1-1099939-5
*Number of
Crimps
Copper Cable Size:
4 AWG–1000 kcmil 1 1 1 1 1 1 1 1
Aluminum Connector Type Anderson Blackburn®Burndy Ilsco Panduit T & B Penn-
Union
Dual-Rated Aluminum Splices VACS ASP YS-A AS SA 60507 to 60584 PIK
BCUA
Dual-Rated Aluminum Lugs VACL ATL YA-A
YA-A-TN
ACL, ACN
2ACL, 2ACN
LAA
LAB
60106 to 60184
60230 to 60284 BLUA
*Number of
Crimps
Cable Size: 6 AWG–500 kcmil 1 1 1 1 1 1 1
Cable Size: 600 kcmil–800 kcmil 2 1 1 1 2 1 1
Cable Size: 1000 kcmil 2 2 2 2 2 2 2
* When crimping with the RK12ID crimping tool, use the number of crimps listed in this table
instead of the number provided with the connector.

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Maintenance
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Schedule
Each Operating Day
Before use:
1. Inspect indenter and head for wear or damage such
as cracks, gouges, or chips.
2. Inspect the tool for damage or leaks. If damage
is detected, return the tool to a Greenlee Utility
Authorized Service Center for inspection.
Skin injection hazard:
• Do not use hands to check for
leaks.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punctures
skin, causing serious injury, gangrene,
or death. If you are injured by escap-
ing oil, seek medical attention
immediately.
After use:
1. Wipe all tool surfaces clean with a damp cloth and
mild detergent.
2. Place tool in the carrying case. Store in a cool, dry
place.
Monthly
1. Thoroughly clean all surfaces.
2. Oil the pin joints and metal surfaces that slide.
Annually or After 10,000 Cycles
Return the tool to a Greenlee Utility Authorized Service
Center for inspection.
Periodic Pressure Relief Valve Check
Pinch points:
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.
The crimping tool’s relief valve may require occasional
adjustment. To determine whether this adjustment is
necessary, periodically test the crimping tool with a
Greenlee 50013408 test meter, 50065750 sensor,
and 52024054 adapter (purchased separately).
1. Install the Greenlee 50065750 sensor into the
52024054 adapter, as shown below.
52024054
Adapter
50065750
Sensor

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Maintenance (cont’d)
Periodic Pressure Relief Valve Check
(cont’d)
2. Lift the latch to open the crimping head and install
the adapter between the indenter and crimp head.
Position the round end of the adapter against the
indenter and close the crimp head against the
V-surfaces on the adapter, as shown below.
Check that the head and latch are fully engaged.
3. Connect the sensor cable to the test meter and cali-
brate the sensor per operating instructions provided
with the 50013408 test meter.
4. Advance the indenter until the pressure relief valve
activates. The display on the test meter should
show a force of 24,250 to 24,925 lb (107.8 to
110.8kN). If the force reading is outside this range,
send the crimping tool to an authorized service
center for adjustment.
Relief valve adjustments must be done by an autho-
rized service center.
Verify Crimping Distance
The crimping distance on this tool is set at the factory
to a precise dimension to insure a certied crimp. The
crimping distance may require resetting if the indenter,
crimping head, or other components are replaced on
the tool. Follow the procedure below to verify and reset
the crimping distance.
1. Close the crimping head and check that latch and
head are fully engaged.
2. Advance the indenter until the indenter is at full
stroke.
3. Measure the distance between the bottom of the
indenter and the head as shown below. The dis-
tance should measure 0.195" to 0.205" (4.953 mm
to 5.207 mm). If the distance is outside this range,
remove the set screw (9) and indenter (6).
• To increase distance, remove a spacer (4, 5).
• To decrease distance, add a spacer (4, 5).
5.207 mm (0.205")
4.953 mm (0.195")
4. Install the indenter (6) and secure set screw (9).

RK12ID Remote Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Illustration and Parts List
52024011 Head and ram unit (includes 1–12)
1 52020271 Yoke ........................................................ 1
2 O-ring (included in 52054906) ................ 1
3 52020510 Ram......................................................... 1
4 52020512 Spacer, .010 x 1.181 x .531 ....(as needed)
5 50337300 Spacer, .025 x .997 x .549 ......(as needed)
6 52025013 Indenter................................................... 1
7 90513533 Retaining ring.......................................... 4
8 52020513 Pivot pin.................................................. 2
9 Screw, #10-32 x .25 skt set cone pt ....... 1
10 52064268 Crimp head ............................................. 1
11 52020273 Latch ....................................................... 1
12 50111230 Torsion spring ......................................... 2
Key Part No. Description Qty
13 52066861 Spring ..................................................... 1
14 50066897 Screw, M6-1.0 x 80 mm skt head cap.... 1
15 50066900 End cap................................................... 1
16 50043676 Screw, M5-0.8 x 10 mm skt head cap.... 1
17 50066943 Stop ........................................................ 1
18 52066863 Piston cup............................................... 1
19 52066864 O-ring...................................................... 1
20 52066862 Cylinder................................................... 1
21 52065528 Decal, ID ................................................. 1
22 52065823 Coupler kit, 3/8" male ............................. 1
23 52066865 Backup ring............................................. 1
Key Part No. Description Qty
10
6
3
8
8
11
7
1
7
12
7
54
9
12
16
17
7
2
13
14
15
18 19 20
22
21
23

4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
USA Tel: [phone]
Fax: [phone]
Canada Tel: [phone]
Fax: [phone]
International Tel: [phone]
Fax: [phone]
www.greenlee.com