Textron Greenlee RK6040 User manual

INSTRUCTION MANUAL
99946700 REV 4 © 2010 Greenlee Textron Inc. 3/10
RK6040
60-ton, Single-acting,
Die-type Crimping Tool
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

RK6040 60-ton Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The Greenlee Utility 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 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:
50058509 3 m (10') Conductive•
50058517 3 m (10') Non-Conductive•
50058522 7.6 m (25') Non-Conductive•
Safety
Safety is essential in the use and maintenance of
Greenlee Utility tools and equipment. This manual and
any markings on the tool provide information for avoid-
ing 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 Greenlee
Utility 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 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.
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
Maintenance ................................................................. 7
Periodic Relief Valve Check .......................................... 7
Illustration and Parts List ...........................................8–9

RK6040 60-ton 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 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.

RK6040 60-ton Crimping Tool
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- conductive hoses and proper
personal protective equipment.
Failure to observe this warning could
result in severe injury or death.
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
escaping oil, seek medical attention
immediately.
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 assem-
bled tool can 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.

RK6040 60-ton Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
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6
7
5
1
4
3
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)
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, female)
Identification

RK6040 60-ton Crimping Tool
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 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
escaping oil, seek medical attention
immediately.
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 assem-
bled tool can 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 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 uid.
Actuating the tool intermittently will reduce the time
required to warm the uid to an efcient operating
temperature.

RK6040 60-ton Crimping Tool
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- conductive 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: 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 disulde grease is
recommended.
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.
Periodic Relief Valve Check
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 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.

RK6040 60-ton Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Illustration
19 EXPLODED
1
2
3
4
5
6
7
8
5
9
10
44
43
12
14
13
11
16
45 46
47
34
33
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30
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20
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31
13
14
42
50
37
38
36
35
41
40
39
51
17
15
48
26
25
26
25
24
23

RK6040 60-ton Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Parts List
1 50105663 Stand ....................................................1
2 50105671 Lifting ring .............................................1
3 50105680 Screw....................................................2
4 50105698 Block, hook guide.................................2
5 50105701 Pin.........................................................4
6 50105710 Screw....................................................2
7 50105728 Block, oil feed .......................................1
8* O-ring....................................................1
9 50105744 Spring ...................................................1
10 50105760 Holder, ball............................................1
11* Ball ........................................................1
12 50105787 Screw, anchor spring............................1
13* Backup ring...........................................2
14* O-ring....................................................2
15 50105817 Head, cylinder.......................................1
16> Block, handle holder.............................2
17> Pin.........................................................2
18> Handle...................................................1
19 50105876 Driver, center spring..............................1
20* O-ring....................................................1
21* Backup ring...........................................1
22 50105906 Screw....................................................1
23 50105914 Washer..................................................1
24 50105922 Ram.......................................................1
25† Guide, ram ............................................2
26† Pin.........................................................2
27 50105957 Screw, anchor spring............................1
Key Part No. Description Qty Key Part No. Description Qty
28† Pin.........................................................2
29† Spring ...................................................2
30† Pin, die ..................................................2
31† Pin, retainer...........................................2
32† Screw....................................................2
33† Retainer.................................................2
34 50106023 Retainer, holder.....................................1
35< Cap .......................................................1
36< Screw....................................................4
37< Handle, head cap..................................1
38< Pin.........................................................2
39< Spring ...................................................1
40< Pin.........................................................1
41< Screw....................................................2
42< Switch, release......................................1
43 90508076 Coupler, threaded female, 3/8"
(includes item 44)..................................1
44 90501098 Cap, coupler with lanyard.....................1
45> Washer..................................................2
46> Screw....................................................2
47< Wire, connect........................................1
48 50106171 Decal, identication ..............................2
49 50106180 Box, metal ............................................1
50< Decal, pinch hazard ..............................1
51< Decal, warning ......................................1
Kits
* 50017438 Seal kit (includes items
marked with an asterisk)
† 52033900 Die retaIning kit (includes items
marked with †)
> 52054978 Handle assembly kit
< 52054976 Cap hardware kit

USA 800-435-0786 Fax: [phone]
815-397-7070 Fax: [phone]
Canada 800-435-0786 Fax: [phone]
International [phone] Fax: [phone]
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com