Greenlee GATOR CK1240 Bedienungsanleitung

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

GATOR®

CK1240 and CK1240C

Crimping Tools

120 Volt and 230 Volt

Serialnummer

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

All specifications are nominal and may change as design improve-

ments occur. Greenlee Textron Inc. shall not be liable for damages

resulting from misapplication or misuse of its products.

GATOR is a registered trademark of Greenlee Textron Inc.

AVIA is a registered trademark of Avia International.

Mobil is a registered trademark of Mobil Oil Corporation.

NUTO is a registered trademark of Exxon Corporation.

Tellus is a registered trademark of Shell Oil Company.

KEEPTHIS MANUAL

Table of Contents

Description .....................................................................2

Safety .............................................................................2

Purpose of this Manual ..................................................2

Important Safety Information......................................3–5

Identification ...................................................................6

Specifications .................................................................6

Operation .......................................................................7

Die Selection .................................................................. 8

Connector Selection.......................................................8

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

Periodic Pressure Relief Valve Check ...........................9

Troubleshooting ...........................................................10

Disassembly.................................................................11

Assembly......................................................................12

Illustrations and Parts List ......................................13–18

Description

The CK1240 Hydraulic Crimping Tool is a hand-held,

self-contained tool intended to crimp aluminum and

copper connectors onto electrical cable.

The CK1240C has a PVC-covered crimping head.

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 tools:

CK124011 120 Volt Crimping Tool

CK1240C11 120 Volt Crimping Tool

with PVC-covered Head

CK124022 230 Volt Crimping Tool

CK1240C22 230 Volt Crimping Tool

with PVC-covered Head

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

IMPORTANT SAFETY INFORMATION

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 expose to rain.

•Do not use in wet or damp

locations.

Failure to observe these warnings

could result in severe injury or death.

Electric shock hazard:

•Connect the power cord to a

receptacle of proper voltage for

the tool in use on a ground fault-

protected circuit only.

•Do not modify the power cord or

plug.

•Inspect the power cord before use.

Repair or replace the cord if

damaged.

•Do not pull or carry by cord, use

the cord as a handle, close a door

on the cord, run over the cord, or

pull the cord around sharp edges

or corners. Keep the cord away

from heated surfaces.

•Do not unplug by pulling on the

cord. To unplug, grasp and pull the

plug—not the cord.

•Disconnect from power before

servicing.

Failure to observe these warnings

could result in severe injury or death.

Do not use this crimping tool in a

hazardous environment. Hazards

include flammable liquids, gases, or

other materials. Using this crimping

tool in a hazardous environment can

result in a fire or explosion.

Failure to observe this warning will

result in severe injury or death.

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, defined below,

indicates the severity of the hazard. The message

after the signal word provides information for

preventing or avoiding the hazard.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Hazards which, if not avoided, COULD result in

severe injury or death.

Immediate hazards which, if not avoided, WILL

result in severe injury or death.

SAFETY

ALERT

SYMBOL

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.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

IMPORTANT SAFETY INFORMATION

An incomplete crimp can cause a fire.

•Use proper die, connector, and cable combina-

tions. Improper combinations can result in an

incomplete crimp.

•An audible “pop” indicates that the crimping tool

has achieved a complete crimp. If you do not

hear a “pop,” the crimp is incomplete.

Failure to observe these warnings could result in

severe injury or death.

Do not operate the tool while wearing loose clothing.

Loose clothing can get caught in moving parts.

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

flying 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, gangrene, or

death.

Do not use solvents or flammable

cleaners to clean the tool body.

Solvents could ignite, causing

serious injury or property damage.

Pinch points:

Keep hands away from the crimping

tool head when crimping.

Failure to observe this warning could

result in severe injury or death.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

Note: Keep all decals clean and legible, and replace

when necessary.

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.

IMPORTANT SAFETY INFORMATION

Inspect tool before use. Replace any worn or

damaged parts with Greenlee replacement 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.

•Do not operate the tool without dies. Damage to

the ram or crimping tool head can result.

•This tool is not designed for continuous use.

After 30 to 40 crimping cycles, allow the crimping

tool to cool for 15 minutes.

•Do not place the tool in a vise. The crimping tool

is designed for hand-held operation.

•Ensure that all bystanders are away from the

work area when operating the tool.

•Ensure that the work area is clean, dry,

uncluttered, and well-lit.

• Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

Extension cords:

•Use only 16, 14, or 12 AWG

extension cords.

• Do not use extension cords that

are longer than 30 m (100').

•Repair or replace damaged

extension cords.

Failure to observe these warnings

could result in severe injury or death.

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

Identification

Specifications

CK1240 and CK1240C

1. Housing

2. Retract Button

3. Power Cord

4. Trigger

5. Die Release Buttons

Crimping Tool

Length...............................................................................................396 mm (15.6")

Width...................................................................................................80 mm (3.16")

Height ..................................................................................................279 mm (11")

Mass/Weight ..................................................................................... 6.3 kg (13.9 lb)

Sound Level...........................................................................< 75 dB (A) at 1 meter

Vibration.................................................................................................... < 2.5 m/s2

Motor Voltage

CK124011 and CK1240C11.............................................120 VAC, 60 Hz, 2.1 A

CK124022 and CK1240C22.............................................230 VAC, 50 Hz, 1.1 A

Hydraulic Oil ....................................................50 ml (0.1 pint) of Shell Tellus®T 15

Recommended Operating Temperature Range.... –15 °C (5 °F) through 50 °C (120 °F)

Crimping Capacities

Crimping Range........................................................................ 8 AWG to 750 kcmil

Crimping Force ...............................................................................106 kN (12 tons)

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

Operation

1. Clean the die seat area.

2. Install the proper size and type of crimping dies.

3. 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.

4. Press the release button on the ram body (located in

the cutout) and slide the other die half in. Release

the button and slide the die half until the retainer

snaps and locks the die into place.

5. Follow the connector manufacturer’s instructions

for appropriate cable strip length and surface

preparation.

6. Insert cable fully into connector and center the

connector between the dies.

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

SIDE B

7. Using the sequence illustrated here, press the

trigger to advance the dies. Continue to crimp until

the pressure relief valve activates.

Note: Pressure relief occurs at approximately

106 kN (12 tons) and is indicated by an audible “pop.”

8. After achieving pressure relief, the ram automatically

returns to the start position and the dies retract.

9. 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.

10. Remove the connector from the crimping tool.

Note: After completing the last crimp on an aluminum

connector, wipe off the excess oxide inhibitor.

Pinch points:

Keep hands away from the crimping

tool head when crimping.

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

flying 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, gangrene, or

death.

An incomplete crimp can cause a fire.

•Use proper die, connector, and cable combina-

tions. Improper combinations can result in an

incomplete crimp.

•An audible “pop” indicates that the crimping tool

has achieved a complete crimp. If you do not

hear a “pop,” the crimp is incomplete.

Failure to observe these warnings could result in

severe injury or death.

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

Die Selection

Crimps made on copper cable with Greenlee

KC12-type dies and the copper connectors

listed here are cUL and UL classified.

Refer to “Connector Selection” for brand names

and model numbers of appropriate lugs as well

as crimping instructions.

Connector Barrel Anderson Blackburn®FCI Burndy Ilsco Panduit T&B Penn- No. of

Type Type Union Crimps*

Copper Short VHSS CSP YS-L CT SCSS/SCS 54504–54523-TB BCU

Splice Long VHS CU YS CTL SCL/SCH 54804–54823 BBCU

Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54104–54123-TB BLU

Copper YA/YA-L-TC/YA-L-2TC CRC LCD/LCAN 54204–54223

Lugs YA/YAZ CRA-L/CRB-L 54930BE–54923BE

Long VHCL CTL-L/LCN YA-2N/YA-2TC CRA-2L/CRB-2L LCB/LCC 54850BE–54880BE BBLU

YAZ-2N/YAZ-2TC CRC-2L

Catalog UPC Cable Color No. of

Number Number Size Code 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

Connector Selection

Tool Range: 8 AWG to 750 kcmil

When used with KC12-type dies, this tool is cUL and UL classified for use with the following connector brands:

Dies for Copper Connectors

*Use the number of crimps listed in this column instead of the number provided with the connector.

95R7

8 AWG to

250 kcmil:

1 crimp

300 to

750 kcmil:

2 crimps

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

Maintenance

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from

flying 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, gangrene, or

death.

Do not use solvents or flammable

cleaners to clean the tool body.

Solvents could ignite, causing

serious injury or property damage.

Daily

Before use:

1. Inspect dies for wear or damage, such as cracks,

gouges, or chips.

2. Inspect the crimping tool for damage or leaks.

After use:

1. Use a damp cloth and mild detergent to clean the

housing. Allow the housing to dry.

2. Fully retract the ram. Place the crimping tool in the

carrying case and store in a cool, dry place.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

3. Perform the “Periodic Pressure Relief Valve Check.”

Annually or After 10,000 Crimps

1. Replace the hydraulic oil.

2. Send the tool to an authorized Greenlee service

center for inspection.

Checking the Oil Level

1. Remove the two screws that retain the tank housing

cover. Remove the tank housing cover.

2. Point the crimping head downward and remove the

oil reservoir plug. Fill reservoir if necessary.

3. Replace the oil plug and tank housing cover.

Recommended Hydraulic Oils

AVIA®HVI 15

Shell Tellus T 15

Mobil®DTE 11M

NUTO®H 15

Periodic Pressure ReliefValve Check

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 model 35887 Load Cell (purchased

separately).

1. Insert the test die into the tool (refer to steps 3 and 4

under “Operation” in this manual). Position the load

cell so that the load cell piston is centered between

the two test dies.

2. Press the trigger until the crimping tool achieves

pressure relief and note the position of the needle

when the pressure relief is achieved. The needle

should indicate the “12T” range; if the needle is

outside of this range, send the crimping tool to an

authorized service center for adjustment.

Note: If some other type of load cell is used, the ratio

between the area of the tool and the area of the load

cell may be different. The appropriate corresponding

pressure range depends upon this ratio.

Relief valve adjustments must be done by an

authorized service center.

Pinch points:

Keep hands away from the crimping

tool head when crimping.

Failure to observe this warning could

result in severe injury or death.

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

CK1240 and CK1240C CrimpingTools

Troubleshooting

Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.

of tool.

Tool components worn or damaged. Return tool to an authorized

Greenlee service center.

Dies stop during operation. Oil level is low. Check oil level. Refill reservoir.

Air in hydraulic system. Pull trigger and hold retract button

simultaneously. Hold for approximately

10 seconds.

Tool loses oil. Damaged internal seal. Return tool to an authorized

Greenlee service center.

Oil plug not installed properly. Refill reservoir and replace plug.

Problem Probable Cause Probable Remedy

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