Greenlee HK1240 Bedienungsanleitung

INSTRUCTION MANUAL

HK1240 and HK1240C

Hydraulic Crimping Tools

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

HK1240 and HK1240C Hydraulic Crimping Tools

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

Description

The HK1240 Hydraulic Crimping Tool is a hand-

held, self-contained crimping tool intended to crimp

aluminum and copper connectors onto electrical cable.

It uses industry standard 12-ton U type dies, purchased

separately.

The HK1240C has a PVC-covered crimping head.

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 instruction manual is intended to familiarize opera-

tors and maintenance personnel with the safe operation,

troubleshooting, and repair procedures for the Greenlee

HK1240 and HK1240C.

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 Tools, Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

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

Die Selection ................................................................. 7

Connector Selection...................................................... 7

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

Illustrations and Parts List ........................................9–12

HK1240 and HK1240C Hydraulic Crimping Tools

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 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

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

leaks.

• Depressurize the hydraulic system

before servicing.

Oil under pressure easily punctures

skin causing serious injury, gan-

grene, or death. If you are injured by

escaping oil, seek medical attention

immediately.

HK1240 and HK1240C Hydraulic Crimping Tools

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

IMPORTANT SAFETY INFORMATION

An incomplete crimp can cause a re.

• Use proper connector and cable combinations.

Improper combinations can result in an incomplete

crimp.

• The handle load will drop suddenly to indicate a

completed crimp. If the handle load does not drop

suddenly, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

Inspect tool before use. Replace any worn or

damaged 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.

• This tool is intended for two-handed operation.

Maintain a rm grip on both handles during opera-

tion. Using this tool in any other manner can result

in injury or property damage.

• Do not operate the tool without a connector in

place. Damage to the ram or crimping tool head

can result.

• 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 these precautions may result in

injury and property damage.

Note: Keep all decals clean and legible, and replace

when necessary.

HK1240 and HK1240C Hydraulic Crimping Tools

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

Identiﬁcation

Speciﬁcations

Crimping Tool

Length .............................................................................................552 mm (21.75")

Width.....................................................................................................74 mm (2.9")

Mass/Weight ......................................................................................6.1 kg (13.4 lb)

Hydraulic Oil....................................... 50 ml (0.1 pint) biodegradable hydraulic uid

Crimping Capacities

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

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

HK1240 and HK1240C

1. Die Release Button

2. Die Release Button

3. Handle

4. Return Lever

5. Handle with Reservoir

6. Crimping Head

HK1240 and HK1240C Hydraulic Crimping Tools

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

Operation

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

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

leaks.

• Depressurize the hydraulic system

before servicing.

Oil under pressure easily punctures

skin causing serious injury, gan-

grene, or death. If you are injured by

escaping oil, seek medical attention

immediately.

An incomplete crimp can cause a re.

• Use proper connector and cable combinations.

Improper combinations can result in an incomplete

crimp.

• The handle load will drop suddenly to indicate a

completed crimp. If the handle load does not drop

suddenly, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

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.

7. Using the sequence illustrated here, pump the

handles to advance the dies. Continue to pump 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 specied by the manufacturer.

10. Remove the connector from the crimping tool.

11. Press the trigger lock upward to lock the trigger.

Note: After completing the last crimp on an alumi-

num connector, wipe off the excess oxide inhibitor.

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

SIDE B

HK1240 and HK1240C Hydraulic Crimping Tools

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

Die Selection

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

Crimps made with this tool and KC12-type or KA12-type dies are cUL and UL classied when used with the appropriate

conductor and connectors listed below.

Dies for Copper Connectors

Catalog

Number

UPC

Number

Cable

Size Color Code No. of

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

Dies for Aluminum Connectors

Catalog

Number

UPC

Number

Cable

Size Color Code No. of

Crimps

KA12-8 22084 8 AWG Blue 1

KA12-6 22085 6 AWG Gray 1

KA12-4 22086 4 AWG Green 1

KA12-2 22087 2 AWG Pink 1

KA12-1 22088 1 AWG Gold 1

KA12-1/0 22089 1/0 AWG Tan 1

KA12-2/0 22090 2/0 AWG Olive 2

KA12-3/0 22121 3/0 AWG Ruby 2

KA12-4/0 22122 4/0 AWG White 2

KA12-250 22123 250 kcmil Red 2

KA12-300 22124 300 kcmil Blue 2

KA12-350 22125 350 kcmil Brown 2

KA12-400 22126 400 kcmil Green 3

KA12-500 22127 500 kcmil Pink 3

KA12-600 22128 600 kcmil Black 3

KA12-750 22129 750 kcmil Yellow 3

Connector Selection (NOT for use with ﬂex, navy, or welding wire)

Tool Range: 8 AWG to 750 kcmil

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

Short

Long

Short

Long

BARREL

TYPE

8 AWG to

250 kcmil:

1 crimp

300 to

750 kcmil:

2 crimps

NUMBER

OF CRIMPS*

VHSS

VHS

VHCS

VHCL

ANDERSON

CSP

CTL-2/CTL

CTL-L/LCN

BLACKBURN®

YS-L

YA-2LN/

YA-L/YA-2L;

YA/YA-L-TC/

YA-L-2TC

YA/YAZ

YA-2N/YA-2TC

YAZ-2N/YAZ-2TC

BURNDY

CTL

CSW

CRA/CRB

CRC

CLN, CLW

CRA-L/CRB-L

CRA-2/CRB-2L

CRC-2L

ILSCO

SCSS

SCS

SCL

SCH

LCAS

LCA

LCD

LCAN

LCB

LCC

PANDUIT

54504 to

54523-TB

54804 to

54823

54104 to

54123-TB;

54204 to

54223

54930BE to

54923BE;

54850BE to

54880BE

T&B

BCU

BBCU

BLU

BBLU

PENN-

UNION

CONNECTOR

TYPE

Copper

Splices

Copper

Lugs

When used with KA12-type dies, this tool is cUL and UL classied for use with the following connector brands:

8 to

1/0 AWG:

1 crimp

2/0 AWG to

350 kcmil:

2 crimps

400 to

750 kcmil:

3 crimps

NUMBER

OF CRIMPS*

ANDERSON

VACS

VACL

BLACKBURN®

ASP

ATL

BURNDY

YS-A

YA-A

YA-ATN

ILSCO

ASN

ACL/ACN

2ACL/2ACN

ALNS/ALNN/ALND

PANDUIT

LAA

LAB

T&B

60501 to

60578

60101 to

60176;

60230 to

60278

PENN-

UNION

PIK

BLUA

CONNECTOR

TYPE

Dual-rated

Aluminum

Splices

Dual-rated

Aluminum

Lugs

95R7

* Use the number of

crimps listed in this

column instead of the

number provided with

the connector.

HK1240 and HK1240C Hydraulic Crimping Tools

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

Periodic Pressure Relief Valve Check

Pinch points:

Keep hands away from closing dies.

Failure to observe this warning could

result in severe injury or death.

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 dies 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. Pump the lever until crimping tool achieves pres-

sure 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 pres-

sure range depends upon this ratio.

HK1240 and HK1240C Hydraulic Crimping Tools

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

Illustration

HK1240 and HK1240C Hydraulic Crimping Tools

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

Illustration

203

202

201

200

204

102

103

107

106

104

105

108

114

112

111

120

123

115

125

122

101

126

121

124

113

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