Textron Greenlee RK1240 User manual

INSTRUCTION MANUAL
RK1240 and RK1240C
12-ton, Single-acting,
Die-type Crimping Tools
99926989 © 2011 Greenlee Textron Inc. IM 1337 REV 7 9/11
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 Codes GAB and ADL

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The Greenlee RK1240 12-ton, Single-acting, Die-type
Crimping Tool is intended to crimp splicing sleeves
and termination lugs using industry standard dies.
The single-acting ram requires hydraulic pressure to
advance, and uses an internal spring to return.
The RK1240C has a PVC-covered crimping head.
These crimping tools require an external 700 bar
(10,000psi) hydraulic power source, such as
Greenlee 975, 976-22, 980, and 980-22. They may
also be powered using a hydraulic intensier capable
of developing 700 bar (10,000 psi), such as the
GreenleeUtility Dynapress®.
Optional accessories include the following hydraulic
hoses with one male and one female coupler:
• 90558509 3 m (10') Conductive
• 90558517 3 m (10') Non-Conductive
• 90558522 7.6 m (25') Non-Conductive
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 tools:
• RK1240 — Serial Code GAB
• RK1240C — Serial Code ADL
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.
Dynapress is a registered trademark of Greenlee Textron Inc.
Loctite is a registered trademark of the Loctite Corporation.
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
Setup ............................................................................ 6
Operation ...................................................................... 7
Die Selection ................................................................. 8
Connector Selection...................................................... 8
Maintenance ................................................................. 9
Periodic Relief Valve Check .......................................... 9
Assembly..................................................................... 10
Illustration and Parts List .......................................11–12

RK1240 and RK1240C Crimping Tools
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 will
result in severe injury or death.
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.

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
IMPORTANT SAFETY INFORMATION
Electrical shock hazard:
This tool is not insulated. When using
this unit near energized electrical
lines, use only certied non-con-
ductive hoses and proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
Skin injection hazard:
• Do not use ngers or hands to
check for leaks.
• Depressurize hydraulic system
before servicing.
High pressure oil easily punctures
skin causing serious injury, gangrene
or death. If injured seek medical help
immediately to remove oil.
Wear eye protection when using this
tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Pinch points:
Keep hands away from closing dies.
Failure to observe this warning could
result in severe injury or death.
Use proper die, connector, and wire combinations.
Mismatched components can result in an incomplete
crimp. Failure to complete a crimp could result in
severe injury, death, or re if a connection separates
or if it has high electrical resistance.
Inspect tool and dies before use. Replace any worn or
damaged parts. A damaged or improperly assembled
tool could break and strike nearby personnel with suf-
cient force to cause severe injury or death.
• 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 informa-
tion supplied with the hydraulic power source.
Note: Keep all decals clean and legible, and replace
when necessary.

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Specifications
Weight.......................................................................................................4.4 kg (9.7 lb)
Length..................................................................................................302 mm (11.88")
Width ...................................................................................................74.2 mm (2.92")
Height ........................................................................................................127 mm (5")
Stroke (with dies).....................................................................................42 mm (1.65")
Die Type...............................................................................................Standard U-type
Crimp Force.......................................................................... 10.9 metric tons (12 tons)
Crimp Capacity...........................................................750 kcmil copper and aluminum
lugs, taps, and splices
Power Source Required .................................................................700 bar (10,000 psi)
RK1240 and RK1240C
1. Die Release Button
2. Die Release Button
3. Head Die Retaining Pin
4. Ram Die Retaining Pin
5. Hot Stick Adapter
(thread size 5/16-18 UNC)
6. Hydraulic Coupling
(3/8 threaded)
1
2
3
4
6
5

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Setup
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.
Skin injection hazard:
• Do not use ngers or hands to
check for leaks.
• Depressurize hydraulic system
before servicing.
High pressure oil easily punctures
skin causing serious injury, gangrene
or death. If injured seek medical help
immediately to remove oil.
Wear eye protection when using this
tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Use proper die, connector, and wire combinations.
Mismatched components can result in an incomplete
crimp. Failure to complete a crimp could result in
severe injury, death, or re if a connection separates
or if it has high electrical resistance.
Inspect tool and dies before use. Replace any worn or
damaged parts. A damaged or improperly assembled
tool could break and strike nearby personnel with suf-
cient force to cause severe injury or death.
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 informa-
tion 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 C-head 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 ram body
(located in the cutout) and slide the other die half
in. Release the button and slide the die until the
retainer snaps and locks into place.

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Operation
Electrical shock hazard:
This tool is not insulated. When using
this unit near energized electrical
lines, use only certied non-con-
ductive hoses and proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
Pinch points:
Keep hands away from closing dies.
Failure to observe this warning could
result in severe injury or death.
Note: When using KC12-type dies, complete the
number of crimps listed on the “Connector Selection”
chart in this manual. For other dies, complete the
number of crimps specified by the manufacturer.
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 as shown.
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 the “Periodic Relief Valve Check” in this
manual.
5. Stop the power source and allow the ram to retract.

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Die Selection
Refer to “Connector Selection” for brand names and model numbers of appropriate lugs as well as crimping instructions.
Crimps made with this tool and KC12-type or KA12-type dies are cUL and UL classied when used with the appropriate
conductor and connectors listed below.
Dies for Copper Connectors
Catalog
Number
UPC
Number
Cable
Size Color Code No. of
Crimps
KC12-8 10996 8 AWG Red 1
KC12-6 10997 6 AWG Blue 1
KC12-4 10998 4 AWG Gray 1
KC12-2 10999 2 AWG Brown 1
KC12-1 11003 1 AWG Green 1
KC12-1/0 11004 1/0 AWG Pink 1
KC12-2/0 11007 2/0 AWG Black 1
KC12-3/0 11010 3/0 AWG Orange 1
KC12-4/0 11011 4/0 AWG Purple 1
KC12-250 11012 250 kcmil Yellow 1
KC12-300 11013 300 kcmil White 2
KC12-350 11014 350 kcmil Red 2
KC12-400 11015 400 kcmil Blue 2
KC12-500 11016 500 kcmil Brown 2
KC12-600 11018 600 kcmil Green 2
KC12-750 11020 750 kcmil Black 2
Dies for Aluminum Connectors
Catalog
Number
UPC
Number
Cable
Size Color Code No. of
Crimps
KA12-8 22084 8 AWG Blue 1
KA12-6 22085 6 AWG Gray 1
KA12-4 22086 4 AWG Green 1
KA12-2 22087 2 AWG Pink 1
KA12-1 22088 1 AWG Gold 1
KA12-1/0 22089 1/0 AWG Tan 1
KA12-2/0 22090 2/0 AWG Olive 2
KA12-3/0 22121 3/0 AWG Ruby 2
KA12-4/0 22122 4/0 AWG White 2
KA12-250 22123 250 kcmil Red 2
KA12-300 22124 300 kcmil Blue 2
KA12-350 22125 350 kcmil Brown 2
KA12-400 22126 400 kcmil Green 3
KA12-500 22127 500 kcmil Pink 3
KA12-600 22128 600 kcmil Black 3
KA12-750 22129 750 kcmil Yellow 3
Connector Selection
Tool Range: 8 AWG to 750 kcmil
When used with KC12-type dies, this tool is cUL and UL classied for use with the following connector brands:
Short
Long
Short
Long
BARREL
TYPE
8 AWG to
250 kcmil:
1 crimp
300 to
750 kcmil:
2 crimps
NUMBER
OF CRIMPS*
VHSS
VHS
VHCS
VHCL
ANDERSON
CSP
CU
CTL-2/CTL
CTL-L/LCN
BLACKBURN®
YS-L
YS
YA-2LN/
YA-L/YA-2L;
YA/YA-L-TC/
YA-L-2TC
YA/YAZ
YA-2N/YA-2TC
YAZ-2N/YAZ-2TC
BURNDY
CT
CTL
CSW
CRA/CRB
CRC
CLN, CLW
CRA-L/CRB-L
CRA-2/CRB-2L
CRC-2L
ILSCO
SCSS
SCS
SCL
SCH
LCAS
LCA
LCD
LCAN
LCB
LCC
PANDUIT
54504 to
54523-TB
54804 to
54823
54104 to
54123-TB;
54204 to
54223
54930BE to
54923BE;
54850BE to
54880BE
T&B
BCU
BBCU
BLU
BBLU
PENN-
UNION
CONNECTOR
TYPE
Copper
Splices
Copper
Lugs
When used with KA12-type dies, this tool is cUL and UL classied for use with the following connector brands:
8 to
1/0 AWG:
1 crimp
2/0 AWG to
350 kcmil:
2 crimps
400 to
750 kcmil:
3 crimps
NUMBER
OF CRIMPS*
ANDERSON
VACS
VACL
BLACKBURN®
ASP
ATL
BURNDY
YS-A
YA-A
YA-ATN
ILSCO
AS
ACL/ACN
2ACL/2ACN
PANDUIT
SA
LAA
LAB
T&B
60501 to
60578
60101 to
60176;
60230 to
60278
PENN-
UNION
PIK
BLUA
CONNECTOR
TYPE
Dual-rated
Aluminum
Splices
Dual-rated
Aluminum
Lugs
95R7
* Use the number of
crimps listed in this
column instead of the
number provided with
the connector.

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
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 disulde grease is
recommended.
• Inspect the hydraulic hoses periodically.
• Periodically verify that the power source reaches
700 bar (10,000 psi). Refer to the “Periodic Relief
Valve Check” in this manual.
Periodic Relief Valve Check
Skin injection hazard:
• Do not use ngers or hands to
check for leaks.
• Depressurize hydraulic system
before servicing.
High pressure oil easily punctures
skin causing serious injury, gangrene
or death. If injured seek medical help
immediately to remove oil.
Wear eye protection when using this
tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Pinch points:
Keep hands away from closing dies.
Failure to observe this warning could
result in severe injury or death.
Inspect tool and dies before use. Replace any worn or
damaged parts. A damaged or improperly assembled
tool could break and strike nearby personnel with suf-
cient force to cause severe injury or death.
• 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.
Periodically verify that your hydraulic power source
is supplying between 9600 and 10,400 psi (662 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 ow 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 ow from your
power source. The ram will retract.
If crimp pressures are low, the hydraulic power source
relief valve may need adjustment.
Relief valve adjustments must be performed accord-
ing to the instructions provided with the hydraulic
power source.

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Step 4. Installing the Ram
Assembly (refer to the Illustration)
1. Lubricate the Die Retainer (4) and Die Release
Button (2) with a Molybdenum Disulde grease.
Assemble them into the C-head and install Drive
Pin (3). Add two drops of Loctite®242® Threadlocker
to Screw (6), install Spring (5) from the top of the
C-head and retain with Screw (6). Adjust the Screw
(6) so that the Die Retainer (4) is ush with the head
when the Die Release Button (2) is pressed.
2. Inspect the external surface of the ram and the
inside surface of the cylinder for nicks, gouges or
other imperfections. Replace the ram or cylinder if
necessary.
3. Assemble Spring (11), Die Retaining Pin (10) and Die
Release Button (12) to the Ram (15). Retain with the
Roll Pin (9).
4. Tilt and slide the ram (15) through the opening in
the C-head (1). Align the T-shaped protrusion on the
ram with the T-shaped groove in the C-head and
assemble the ram to the head (see below).
5. Slide the Washer (16) and Wiper (17) onto the
Ram (15) as far as they will go. Place the U-cup Seal
(21) on the Ram.
6. Assemble the Extension Spring (19) to the two
Spring Retainers (18,20).
7. Thread the Spring Retainer (20) into the base of the
Cylinder (23), use a 5mm Allen wrench to tighten the
spring retainer.
8. Lubricate the O-ring (22) and Backup Ring (21) and
threads on the cylinder and C-head.
9. Slide the ram assembly down the C-head and
assemble into the cylinder (23) far enough for full
O-ring and Backup ring engagement.
10. Slip the cylinder into the base of the C-head and
start threading them together. Continue to thread
the cylinder into the C-head until the cylinder con-
tacts the C-head.
11. Lock the C-head in place with the Set Screw (7) .
12. Install Nylon Washer (14) and 8mm Screw (13)
through the ram and tighten securely.
13. Use Pipe Sealer and assemble the 3/8" NPT Pipe
(24) to the 3/8 Coupler (25). Assemble to the
cylinder.

RK1240 and RK1240C Crimping Tools
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Illustration
6
5
3
2
1
13
14
79
10
11
12
15
16
17
18
19
20
21
23
24
25
4

RK1240 and RK1240C Crimping Tools
Parts List
Key Part No. Description Qty
1 50053299 Head, crimping.......................................................................................... 1
50072226 Head, PVC-covered .................................................................................. 1
2 50053175 Button, release.......................................................................................... 1
3 90550633 Pin, groove 3 mm x 16 mm....................................................................... 1
4 50053191 Pin, die retaining ....................................................................................... 1
5 50038214 Spring, compression................................................................................. 1
6 90550609 Screw, set M12 x 1.75 x 12 mm ............................................................... 1
7 90550617 Screw, set M5 x .8 x 5 mm ....................................................................... 1
9 90550641 Pin, roll 3 mm x 10 mm ............................................................................. 1
10 50053167 Pin, die retaining ....................................................................................... 1
11 50038214 Spring, compression................................................................................. 1
12 50053183 Shaft, release ............................................................................................ 1
13 90550650 Screw, socket head cap M8 x 1.75 x 30 mm............................................ 1
14 50134965 Washer, nylon............................................................................................ 1
15 50053329 Ram, 42 mm.............................................................................................. 1
16 50052632 Washer, steel............................................................................................. 1
17 50053019 Wiper, leather ............................................................................................ 1
18 50053345 Retainer, spring ......................................................................................... 1
19 50053361 Spring, extension ...................................................................................... 1
20 50053388 Retainer, spring ......................................................................................... 1
21 90552067 Seal, U-cup ............................................................................................... 1
23 50053396 Cylinder, 42 mm ........................................................................................ 1
24 50413642 Nipple, pipe, 3/8 NPT hex......................................................................... 1
25 50419411 Coupler, hydraulic, Parker #3010-3 .......................................................... 1
50418341 Cap, plastic
50487426 Decal, warning
50054686 Carrying case, metal
50054694 Lid liner, warning
50054716 Lid liner, instructions
50054732 Decal, identication
50062140 Decal, warning
50112171 Decal, connector compatibility
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
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