Textron Greenlee RK1550FT Bedienungsanleitung

INSTRUCTION MANUAL

RK1550

15-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.

Serial Codes GAE

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Description

The Greenlee RK1550 15-ton, single-acting, die-type

crimping tool is intended to crimp splicing sleeves

and termination lugs using Kearney PH14 dies

(not included). Adapters are also available to allow

it to be used with Thomas & Betts 15-ton dies,

Burndy 15-ton dies, Kearney 12-ton dies, and industry

12-ton U-style dies.

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 develop-

ing 700 bar (10,000 psi), such as the Greenlee Utility

Dynapress®.

Optional accessories include the following hoses with

one male and one female coupler:

• 90558509 3 m (10') Conductive Hydraulic Hose

• 90558517 3 m (10') Non-Conductive

Hydraulic Hose

• 90558522 7.6 m (25') Non-Conductive

Hydraulic Hose

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 tool:

RK1550 15-ton, Single-acting, Die-type

Crimping Tool — Serial Code GAE

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

Adapter Kits................................................................5–9

Specications.............................................................. 10

Setup ......................................................................10–11

Operation..................................................................... 11

Die Selection ............................................................... 12

Connector Selection.................................................... 12

Maintenance................................................................ 13

Periodic Relief Valve Check......................................... 13

Assembly..................................................................... 14

Illustration and Parts List........................................15–16

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 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

700bar (10,000 psi).

Failure to observe this warning will result in severe

injury or death.

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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.

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Adapter Kits

Procedure for Using Kearney PH14 Dies

1. No die holder assemblies are needed. Dies t

directly into tool.

2. Select proper die set for tting to be crimped.

Note: Do not use non-butting dies (crimps con-

trolled by tonnage) in this tool, as damage could

occur to connectors and/or conductors.

PH14 DIES

BOTTOM DIE

RETAINING

SPRING

PLUNGERS (6)

TOP DIE

HOLDER

RETAINING

SPRING

PLUNGER (6)

3. Install upper die in hole in top of “C” head. Snap in

place with top die retaining plunger (6).

4. Install lower die in hole in end of piston. Snap in

place with bottom die retaining plungers (6).

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Adapter Kits (cont’d)

Procedure for Using Kearney PH2 Dies

48824 Die Holder Kit

1. Install 48823 PH2 die spacer assembly into hole

in top of “C” head. Snap in place with retaining

spring plunger (6).

2. Install upper 48825 die holder assembly into hole in

die spacer assembly. Lock in place with die spacer

retaining screw.

3. Install lower 48825 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

4. Select proper die set for tting to be crimped.

Note: Do not use non-butting dies (crimps con-

trolled by tonnage) in this tool, as damage could

occur to connectors and/or conductors.

5. Slide die into place in top die holder tight against

shoulder. Detent screw will snap into groove of

die. Lock in place with top die retaining cap screw.

Repeat operation for other die entry.

PH2 Die Holder Kit 48824 contains:

(1) 48823 and (2) 48825 Die Holders

TOP DIE HOLDER

RETAINING SPRING

PLUNGER (6)

48823 PH2

DIE SPACER

ASSEMBLY

DETENT SCREWS

TOP DIE

RETAINING

SCREW 48825 PH2

DIE HOLDER

ASSEMBLIES

BOTTOM DIE

RETAINING

SCREW

TOP DIE HOLDER

RETAINING SCREW

BOTTOM DIE

HOLDER

RETAINING SPRING

PLUNGERS (6)

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Adapter Kits (cont’d)

Procedure for Using Thomas & Betts TBM15 Dies

48788 Die Holder Kit

1. Install the upper 48789 die holder assembly in hole

in top of “C” head. Snap in place with top die holder

retaining spring plunger (6).

2. Install lower 48789 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

48788 Die Holder Kit contains:

(2) 48789 Die Holders

3. Select proper die set for tting to be crimped.

4. Slide top die into place in die holder while depress-

ing die retainer button. Release die button while it

snaps into place, locking die into position. Repeat

operation for other die entry.

48789 TBM15 DIE

HOLDER ASSEMBLIES BOTTOM DIE

HOLDER RETAINING

SPRING PLUNGERS (6)

TOP DIE

HOLDER

RETAINING

SPRING

PLUNGER (6)

BOTTOM DIE

RETAINING MECHANISM

TOP DIE

RETAINING

MECHANISM

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Adapter Kits (cont’d)

Procedure for Using Burndy Y46 Dies

48820 Die Holder Kit

1. Install the upper 48822 die holder assembly in hole

in top of “C” head. Snap in place with top die holder

retaining spring plunger (6).

2. Install lower 48821 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

48820 Die Holder Kit contains (1) each:

48822 Upper Die Holder and 48821 Lower Die Holder

3. Select proper die set for tting to be crimped.

4. Slide top die into place in die holder while simulta-

neously squeezing both retainer buttons. Release

buttons and allow them to snap into place. Repeat

operation for other die entry.

48822 Y46 DIE

HOLDER ASSEMBLY

BOTTOM DIE

HOLDER RETAINING

SPRING PLUNGERS (6)

BOTTOM DIE

RETAINING

MECHANISM (2)

TOP DIE

RETAINING

MECHANISM (2)

TOP DIE

HOLDER

RETAINING

SPRING

PLUNGER (6)

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Adapter Kits (cont’d)

Procedure for Using 12-Ton “U” Dies

48802 Die Holder Kit

1. Install the upper 48803 die holder assembly in hole

in top of “C” head. Snap in place with top die holder

retaining spring plunger (6).

2. Install lower 48803 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

12-Ton “U” Die Holder Kit 48802 contains:

(2) 48803 Die Holders

3. Select proper die set for connector to be crimped.

4. Slide die into place in die holder while depress-

ing die retainer button. Release die button while it

snaps into place, locking die into position. Repeat

operation for other die entry.

TOP DIE HOLDER

RETAINING SPRING

PLUNGER (6)

48803 12-TON “U”

DIE HOLDER ASSEMBLIES

BOTTOM DIE HOLDER

RETAINING SPRING

PLUNGERS (6)

DIE RETAINING MECHANISMS

RK1550 15-ton, Single-acting, Die-type Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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.

Speciﬁcations

Weight ................................................6.41 kg (14 lb 2 oz)

Length ....................................................380 mm (14.96")

Width ......................................................76.2 mm (3.00")

Height ...................................................135.4 mm (5.33")

Stroke (without dies)...................................58 mm (2.28")

Die Type...................most 12-ton and 15-ton w/adapters

Crimp Force............................. 13.6 metric tons (15 tons)

Power Source Required ................... 700 bar (10,000 psi)

Crimp Capacity

*With PH14 Dies (no Adapter Kit needed):

1027 kcmil 48/7 ACSR

*With 48824 Die Holder Kit for PH2 Dies:

477 26/27 ACSR tension,

terminals through 1033 kcmil

With 48788 Die Holder Kit for TBM 15 Dies:

1000 kcmil copper and aluminum ttings

With 48820 Die Holder Kit for Y46 Dies:

1250 kcmil aluminum and

1500 kcmil copper ttings

With 48802 Die Holder Kit for 12-ton “U” Dies:

500 kcmil copper splices,

750 kcmil copper terminals,

350 kcmil aluminum splices,

750 kcmil aluminum terminals

* Do not use non-butting dies (crimps controlled by tonnage)

in this tool, as damage could occur to connectors and/or

conductors.

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