Greenlee GATOR RK425 Bedienungsanleitung

INSTRUCTION MANUAL

GATOR®RK425

Remote Crimping Tool

6-ton • Single-acting

Serial Number

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Description

The RK425 6-ton, Single-acting, Remote Crimping Tool

is a hand-held crimping tool with removable crimping

jaws. The single-acting ram requires hydraulic pressure

to advance, and uses an internal spring to return.

This crimping tool requires an external 10,000psi

(700bar) hydraulic power source, such as Greenlee 975,

976-22, 980, 980-22, and EHP700. The RK425 may

also be powered using a hydraulic intensier capable of

developing 10,000psi (700bar), such as the Greenlee

Dynapress®intensier.

Safety

Safety is essential in the use and maintenance of

Greenlee 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 manual is intended to familiarize all personnel with

the safe operation and maintenance procedures for the

following Greenlee tool:

RK425 Remote Crimping Tool

Keep this manual available to all personnel.

Replacement manuals are available upon request

at no charge at www.greenlee.com.

Do not discard this product or throw away!

For recycling information, go to www.greenlee.com.

All specications are nominal and may change as design

improvements occur. Greenlee Tools, Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

Dynapress and GATOR are registered trademarks of Greenlee Tools,

Inc.

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

Die and Connector Selection ......................................... 8

Maintenance................................................................... 9

Illustrations and Parts Lists .................................... 10–12

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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 10,000psi (700bar).

Failure to observe this warning will result in severe

injury or death.

Electric shock hazard:

This tool is not insulated. When

using this unit on or near energized

electrical lines, use proper personal

protective equipment.

Failure to observe this warning

could result in severe injury or death.

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.

Skin injection hazard:

Do not use hands to check for oil

leaks. Oil under pressure easily

punctures skin. If injured, seek

medical attention immediately to

remove oil.

Failure to observe this warning

could result in serious injury, gan-

grene, or death.

Do not use solvents or ammable

liquids to clean the tool body.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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 this warning could result in severe

injury or death.

Pinch points:

Keep hands away from the crimping

tool head when crimping.

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 improp-

erly assembled tool can break and strike nearby

personnel.

Failure to observe this warning could result in severe

injury or death.

Do not perform any service or maintenance other

than as described in this manual. Injury or damage

to the tool may result.

Failure to observe this precaution may result in injury

and property damage.

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.

IMPORTANT SAFETY INFORMATION

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Identiﬁcation

Speciﬁcations

Length........................................................................................................... 12.6" (320.0 mm)

Diameter ........................................................................................................... 2.3" (58.4 mm)

Weight............................................................................................................... 2.0 lb (0.91 kg)

Crimping Force ...................................................................................................6 tons (53 kN)

1. Lock Pin

2. 3/8" Male Screw-type Coupler

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Operation

Inspect tool and dies before use. Replace any

worn or damaged parts. A damaged or improp-

erly assembled tool can break and strike nearby

personnel.

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

electrical lines, use proper personal

protective equipment.

Failure to observe this warning

could result in severe injury or death.

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.

Pinch points:

Keep hands away from the crimping

tool head when crimping.

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.

Follow the operating instructions and safety informa-

tion supplied with the hydraulic power source.

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Operation (cont’d)

Crimping Procedure

1. Insert conductor into the connector and align the

tool and die on the connector. Start in the center for

splices and “H” frames; and on the end, nearest the

pad, for terminals.

2. 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.

3. Stop the power source and allow the ram to retract.

4. Continue crimping the connector until the correct

number of crimps has been completed. Work from

the center to the outer edges for splices and “H”

frame connectors, alternating sides if possible, for

the best compression connections.

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 this warning could result in severe

injury or death.

Die Selection

Interchangeable dies may be used in the standard die

opening. Dies that may be used include:

• Greenlee KD6 series

• Burndy W and X series

• ILSCO ND series

• Huskie HT58 series

• Panduit CD-2001 series

• Other industry W-type dies

Installing Dies

1. Select the proper dies for the connector to be

crimped.

2. Install dies in jaws making certain that they are

properly secured by the spring-loaded, positive

lock, die buttons.

Preparing Cable

Follow the lug manufacturer’s instructions for appropri-

ate cable strip length.

Crimping Direction

First Compression

Crimping Direction

SIDE A

Crimping Direction

SIDE B

First Compression

SIDE A

First Compression

SIDE B

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CJ22 Jaw and KA22/KC22-type Die Selection

Note: This tool will provide a cUL and UL classiﬁed crimp ONLY when used with the CJ22 jaws

and KA22- or KC22-type dies.

Note: This tool will provide 53 kN (6 tons) of crimping force when used with the CJ22 jaws.

Crimps made on copper cable with Greenlee KC22-type dies and the copper connectors listed here are cUL and UL classied.

Crimps made on copper or aluminum cable with Greenlee KA22-type dies and the dual-rated aluminum connectors listed

here are cUL and UL classied.

Refer to “Connector Selection” for brand names and model numbers of appropriate lugs as well as crimping instructions.

Dies for Dual-rated Aluminum Connectors

Catalog Number UPC Number Cable Size

KA22-8 06744 8 AWG

KA22-6 06745 6 AWG

KA22-4 06746 4 AWG

KA22-2 06747 2 AWG

KA22-1 06749 1 AWG

KA22-1/0 06750 1/0 AWG

KA22-2/0 06751 2/0 AWG

KA22-3/0 06752 3/0 AWG

KA22-4/0 06753 4/0 AWG

KA22-250 06754 250 kcmil

KA22-300 06755 300 kcmil

KA22-350 06756 350 kcmil

Dies for Copper Connectors

Catalog Number UPC Number Cable Size Color Code

KC22-8 03079 8 AWG Red

KC22-6 03080 6 AWG Blue

KC22-4 03081 4 AWG Gray

KC22-2 03082 2 AWG Brown

KC22-1 03083 1 AWG Green

KC22-1/0 03084 1/0 AWG Pink

KC22-2/0 03085 2/0 AWG Black

KC22-3/0 03086 3/0 AWG Orange

KC22-4/0 03087 4/0 AWG Purple

KC22-250 03088 250 kcmil Yellow

KC22-300 03089 300 kcmil White

KC22-350 03090 350 kcmil Red

KC22-400 03091 400 kcmil Blue

KC22-500 03092 500 kcmil Brown

KC22-600B 03094 600 kcmil Green

Connector Selection

CJ22 Crimping Jaw Range: Copper — 8 AWG to 600 kcmil†; Dual-rated Aluminum — 8 AWG to 350 kcmil

When used with KC22-type dies, this tool is cUL and UL classied for use with the following connector brands:

Connector

Type

Barrel

Type Anderson Blackburn®Burndy ILSCO Panduit T&B Penn-

Union†

No. of

Crimps*

Copper

Splice

Short VHSS CSP YS-LsCT SCSS/SCS 54504-54518 BCU

Long VHS CU YSsCTL SCL/SCH 54804-54818 BBCU

Copper

Lugs

Short VHCS CTL-2/CTL

YA-2LN/YA-L/YA-2L

YA/YA-L-TC/YA-L-2TC

CSW

CRA/CRB

LCAS/LCA

LCD

54104-54118

54204-54218 BLU

Long VHCL CTL-L/LCN YA-2N

CLN/CLW

CRA-L/CRB-L

CRA-2L/CRB-2L

LCB/LCC 54930BE-54918BE

54850BE-54876BE BBLU

When used with KA22-type dies, this tool is cUL and UL classied for use with the following connector brands:

Connector Type Barrel Type Anderson Blackburn®Burndy ILSCO Panduit** T&B Penn-

Union

No. of

Crimps*

Dual-rated

Aluminum Splice — VACS ASP YS-A AS

ASN SA 60501-60565 PIK

Dual-rated

Aluminum Lugs — VACL ATL YA-A

YA-ATN

ACL/ACN

2ACL/2ACN

ALNS/ALNN/ALND

LAA/LAB 60101-60166

60230-60267 BLUA

* Use the number of crimps listed in the last column instead of the number provided with the connector:

A — 8 to 1/0 AWG: 1 crimp B — 8 to 2 AWG: 2 crimps

2/0 AWG to 600 kcmil: 2 crimps 1 to 3/0 AWG: 3 crimps

4/0 AWG to 350 kcmil: 4 crimps

** 6 AWG to 350 kcmil

† 500 kcmil maximum with Penn-Union connectors

s8 AWG to 350 kcmil with Burndy copper splices

95R7

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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 lock pin. A molybdenum

disulde grease is recommended.

• Inspect the hydraulic hoses periodically.

• Periodically verify that the power source reaches

10,000psi (700bar). 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.

RK425 Remote Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Key Part No. Description Qty Key Part No. Description Qty

1 52065902 Sheath

52049399 Spring kit (includes 2–6)

2 Bolt, shoulder ............................................ 1

3 Disc............................................................ 1

4 Compression spring .................................. 1

5 Washer....................................................... 1

6 O-ring ........................................................ 1

7 52057496 Screw......................................................... 1

8 50032631 Jaw holder................................................. 1

52049400 Latch kit (includes 9–12)

9 Compression spring .................................. 1

10 Locking pin ................................................ 1

11 Compression spring .................................. 1

12 Pin ............................................................. 1

52049401 Roller kit (includes 13 and 14)

13 Roller ......................................................... 2

14 Ram ........................................................... 1

15 52065527 Decal, ID .................................................... 1

16 52065868 Piston ........................................................ 1

17 52065869 Seal............................................................ 1

18 52065870 Cylinder ..................................................... 1

19 52065901 Grip............................................................ 1

52065823 3/8" male coupler kit (includes 20–23)

20 Seal............................................................ 1

21 Fitting......................................................... 1

22 Coupler...................................................... 1

23 Cap ............................................................ 1

52067054 Tag, connector chart ................................. 1

Illustration and Parts List—RK425

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