Greenlee GATOR CK1240K Bedienungsanleitung

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

GATOR®

CK1240K and CK1240KC

Crimping Tools

120 Volt and 230 Volt

Serialnummer

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

CK1240K and CK1240KC Crimping Tools

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.

Tellus is a registered trademark of Shell Oil Company.

Table of Contents

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

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

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

General Safety Rules ................................................. 3–5

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

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

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

Maintenance................................................................... 8

Periodic Pressure Relief Valve Check ........................... 8

Troubleshooting ............................................................. 9

Service Center Information

Disassembly ................................................................. 10

Assembly...................................................................... 11

Illustrations ............................................................. 12–14

Parts List ................................................................ 15–17

Description

The CK1240K Hydraulic Crimping Tool is a hand-held,

self-contained tool intended to crimp aluminum and

copper connectors onto electrical cable.

The CK1240KC 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:

CK1240K11 120 V Crimping Tool

CK1240KC11 120 Volt Crimping Tool

with PVC-covered Head

CK1240K22 230 Volt Crimping Tool

CK1240KC22 230 Volt Crimping Tool

with PVC-covered Head

Keep this manual available to all personnel.

Replacement manuals are available upon request at

no charge at www.greenlee.com

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

CK1240K and CK1240KC Crimping Tools

SAVE THESE

INSTRUCTIONS

GENERAL SAFETY RULES

Read all instructions. Failure to

follow instructions listed below may

result in electric shock, fire, and/or

serious injury. The term “power tool”

in all of the warnings listed below

refers to your mains-operated

(corded) power tool.

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

Electrical safety:

•Power tool plugs must match

the outlet. Never modify the

plug in any way. Do not use any

adapter plugs with earthed

(grounded) power tools. Unmodi-

fied plugs and matching outlets will

reduce risk of electric shock.

•Avoid body contact with earthed

or grounded surfaces such as

pipes, radiators, ranges, and

refrigerators. There is an

increased risk of electric shock if

your body is earthed or grounded.

•Do not expose power tools to

rain or wet conditions. Water

entering a power tool will increase

the risk of electric shock.

•Do not abuse the cord. Never

use the cord for carrying,

pulling, or unplugging the

power tool. Keep cord away

from heat, oil, sharp edges, or

moving parts. Damaged or

entangled cords increase the risk

of electric shock.

•When operating a power tool

outdoors, use an extension cord

suitable for outdoor use marked

“W-A” or “W”. Use of a cord

suitable for outdoor use reduces

the risk of electric shock.

Failure to observe these warnings

could result in severe injury or death.

Work area safety:

•Keep work area clean and well lit. Cluttered or

dark areas invite accidents.

•Do not operate power tools in explosive

atmospheres, such as in the presence of

flammable liquids, gases, or dust. Power tools

create sparks which may ignite the dust or fumes.

•Keep children and bystanders away while

operating a power tool. Distractions can cause

you to lose control.

Failure to observe these warnings could result in

severe injury or death.

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

CK1240K and CK1240KC Crimping Tools

Personal safety:

•Stay alert, watch what you are doing, and use

common sense when operating a power tool.

Do not use a power tool while you are tired or

under the influence of drugs, alcohol, or

medication. A moment of inattention while

operating power tools may result in serious

personal injury.

•Use safety equipment. Always wear eye

protection. Safety equipment such as dust mask,

non-skid safety shoes, hard hat, or hearing

protection used for appropriate conditions will

reduce personal injuries.

•Avoid accidental starting. Ensure the switch

is in the off-position before plugging in.

Carrying power tools with your finger on the

switch or plugging in power tools that have the

switch on invites accidents.

•Do not overreach. Keep proper footing and

balance at all times. This enables better control

of the power tool in unexpected situations.

•Dress properly. Do not wear loose clothing or

jewelry. Keep your hair, clothing, and gloves

away from moving parts. Loose clothes,

jewelry, or long hair can be caught in moving

parts.

Failure to observe these warnings could result in

severe injury or death.

GENERAL SAFETY RULES

Power tool use and care:

•Do not force the power tool. Use the correct

power tool for your application. The correct

power tool will do the job better and safer at the

rate for which it was designed.

•Do not use the power tool if the switch does

not turn it on and off. Any power tool that

cannot be controlled with the switch is dangerous

and must be repaired.

•Disconnect the plug from the power source

before making any adjustments, changing

accessories, or storing power tools. Such

preventive safety measures reduce the risk of

starting the power tool accidentally.

•Store idle power tools out of the reach of

children and do not allow persons unfamiliar

with the power tool or these instructions to

operate the power tool. Power tools are

dangerous in the hands of untrained users.

•Maintain power tools. Check for misalignment

or binding of moving parts, breakage of parts,

and any other condition that may affect the

power tool’s operation. If damaged, have the

power tool repaired before use. Many

accidents are caused by poorly maintained

power tools.

•Keep cutting tools sharp and clean. Properly

maintained cutting tools with sharp cutting edges

are less likely to bind and are easier to control.

•Use the power tool, accessories, and tool bits,

etc., in accordance with these instructions

and in the manner intended for the particular

type of power tool, taking into account the

working conditions and the work to be

performed. Use of the power tool for operations

different from those intended could result in a

hazardous situation.

Failure to observe these warnings could result in

severe injury or death.

Service:

Have your power tool serviced by a qualified

repair person using only identical replacement

parts. This will ensure that the safety of the power

tool is maintained.

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

CK1240K and CK1240KC Crimping Tools

GENERAL SAFETY RULES

Note: Keep all decals clean and legible, and replace

when necessary.

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.

Electric shock hazard:

•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.

Electric shock hazard:

•Inspect the power cord before use.

Repair or replace the cord if

damaged.

•Disconnect from power before

servicing.

Failure to observe these warnings

could result in severe injury or death.

Pinch hazard:

Keep hands away from the crimping

tool head when crimping.

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 may result.

•This tool is not designed for continuous use.

After 20 crimping cycles, allow the crimping tool

to cool for 20 minutes.

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

is designed for hand-held operation.

Failure to observe these precautions may result in

injury or property damage.

Do not use solvents or flammable

cleaners to clean the tool body.

Solvents could ignite, causing

serious injury or property damage.

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

CK1240K and CK1240KC Crimping Tools

Identification

Specifications

CK1240K and CK1240KC

1. Housing

2. Retract Button

3. Power Cord

4. Trigger

5. Die Release Set Screw

Crimping Tool

Class II tool, double insulated

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

CK1240K11 and CK1240KC11 ........................................ 120 VAC, 60 Hz, 2.1 A

CK1240K22 and CK1240KC22 ........................................ 230 VAC, 50 Hz, 1.1 A

Symbols on Tool

V .................................................................................................................... volts

~.............................................................................................. alternating current

A ............................................................................................................. amperes

Hz ................................................................................................................. hertz

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

CK1240K and CK1240KC Crimping Tools

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. Complete the number of crimps specified by the

connector 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.

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.

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.

Electrical safety:

Avoid body contact with earthed

or grounded surfaces such as

pipes, radiators, ranges, and

refrigerators. There is an increased

risk of electric shock if your body is

earthed or grounded.

Failure to observe this warning could

result in severe injury or death.

Personal safety:

Use safety equipment. Always wear eye

protection. Safety equipment such as dust mask,

non-skid safety shoes, hard hat, or hearing

protection used for appropriate conditions will

reduce personal injuries.

Failure to observe this warning could result in

severe injury or death.

Pinch hazard:

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 84455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

CK1240K and CK1240KC Crimping Tools

Maintenance

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 Oil

Shell Tellus T 15

Periodic Pressure Relief Valve 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.

Personal safety:

Use safety equipment. Always wear eye

protection. Safety equipment such as dust mask,

non-skid safety shoes, hard hat, or hearing

protection used for appropriate conditions will

reduce personal injuries.

Failure to observe this warning could result in

severe injury or death.

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 hazard:

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 94455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070

CK1240K and CK1240KC Crimping Tools

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

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

CK1240K and CK1240KC Crimping Tools

SERVICE CENTER INFORMATION

Disassembly

Main Components

1. Loosen the screw (24). Remove the screw (31) and

stop (30).

2. Unscrew and remove the head assembly.

3. Remove the piston (8). Replace the piston O-ring (6)

and piston backup ring (7).

4. Unscrew two tank cover screws (52) and remove the

tank cover.

5. Remove the hydraulic reservoir plug (76) and drain

the hydraulic fluid.

6. Reinstall the plug.

7. Remove the remaining housing screws (52).

8. Remove the housing half.

9. Remove the switch cover (51) and spring (56).

10. Lift the pump/motor assembly and circuit card from

the housing half.

11. Slide a plastic bag over the circuit card and elec-

tronic subassemblies. Tape the bag shut to protect

the subassemblies from hydraulic oil and other

contamination.

12. Unscrew the shoulder bolt (99) and remove the

release lever (107).

13. Remove screws (108) and separate the gear

housing/motor subassembly from the pump housing.

Pump

1. Use a hooked tool to remove the reservoir O-ring

(80). Gently tug it over the reservoir.

2. Remove the reservoir (74).

3. Remove the pump piston (152).

4. Remove the screw plug (151), washer (153), pump

piston (150), valve stem (156), and spring (155).

Replace the sealing washer (154).

5. Use a piece of tape to mark the side of the relief

that is facing up. (This is a reference point for

reassembly.) Remove the unloading valve by

unscrewing the plug (126).

6. Remove the feeder tube subassembly by unscrew-

ing the feeder tube (78). Replace the oil filter (77).

Remove metal chips from the magnet (82).

7. Remove the threaded bushing (72) and replace the

O-ring (73).

Motor, Gearbox, and Bearing

1. Remove the tamper-proof paper seal (96).

2. Remove two screws (92). Remove the end cap

(102).

3. Apply pressure evenly at three points around the

ball bearing (91) and gently pry the bearing up to

remove it.

4. Remove the eccentric (103), grooved ball bearing

(101), and snap ring (100) subassembly from the

shaft.

5. Remove four screws (93). Remove the mounting

block (109) from the gear housing (94).

6. Use a snap-ring removal tool to remove the snap

ring (100).

7. Unscrew four bolts (not numbered) and hex nuts

(97) from the gear housing (94). Separate the gear

housing from the motor flange (110). Unscrew two

flat head screws (112) to separate the flange from

the motor (90).

SERVICE CENTER INFORMATION

Service:

Have your power tool serviced by a qualified

repair person using only identical replacement

parts. This will ensure that the safety of the power

tool is maintained.

Failure to observe this warning could result in

severe injury or death.

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