Greenlee GATOR CK06AT Bedienungsanleitung

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

GATOR®

CK06AT and CK06ATC

Crimping Tools

120 Volt and 230 Volt

Serialnummer

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

CK06AT and CK06ATC 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

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

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

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

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

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

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

Illustrations .............................................................13–15

Parts List ................................................................16–18

Description

The CK06AT Hydraulic Crimping Tool is a hand-held,

self-contained, dieless crimping tool intended to crimp

aluminum and copper connectors onto electrical cable.

The CK06ATC has a rubber-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:

CK06AT11 120 Volt Crimping Tool

CK06ATC11 120 Volt Crimping Tool

with Rubber-covered Head

CK06AT22 230 Volt Crimping Tool

CK06ATC22 230 Volt Crimping Tool

with Rubber-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

CK06AT and CK06ATC 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

CK06AT and CK06ATC CrimpingTools

IMPORTANT SAFETY INFORMATION

An incomplete crimp can cause a fire.

•Use proper connector and cable combinations.

Improper combinations can result in an incom-

plete crimp.

•The relief valve will sound to indicate a completed

crimp. If you do not hear the sound of the relief

valve, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

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 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.

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

CK06AT and CK06ATC 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 a connector in

place. 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

CK06AT and CK06ATC CrimpingTools

Identification

Specifications

CK06AT and CK06ATC

1. Housing

2. Retract Button

3. Power Cord

4. Trigger

5. Crimping Head

Crimping Tool

Length..................................................................................................355 mm (14")

Width........................................................................................................76 mm (3")

Height ..................................................................................................355 mm (14")

Mass/Weight ....................................................................................... 4.5 kg (9.9 lb)

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

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

Motor Voltage

CK06AT11 and CK06ATC11 ............................................ 120 VAC, 60 Hz, 2.1 A

CK06AT22 and CK06ATC22 ............................................ 230 VAC, 50 Hz, 1.1 A

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

Crimping Capacities

Crimping Range...................................................................... #4 AWG to 500 kcmil

Crimping Force ................................................................................55 kN (6.2 tons)

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

CK06AT and CK06ATC CrimpingTools

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

or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from

flying debris or hydraulic oil.

An incomplete crimp can cause a fire.

•Use proper connector and cable combinations.

Improper combinations can result in an incom-

plete crimp.

•The relief valve will sound to indicate a completed

crimp. If you do not hear the sound of the relief

valve, the crimp is not complete.

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.

Keep hands away from the crimping

tool head when crimping.

Failure to observe this warning could

result in severe injury or death.

Small connectors may become

wedged between the nibs of the

tool. Center the connector

between the four nibs before

crimping.

Failure to observe this precaution

may cause property damage.

RIGHT

WRONG

Preparation

Follow the lug manufacturer’s instructions for appropriate

cable strip length.

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

SIDE B

Crimping

1. Insert cable fully into connector. Center the connec-

tor between the nibs.

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.

2. Pull the trigger to advance the nibs. Hold the trigger

down until the pressure relief valve activates.

Note: Pressure relief occurs at approximately

690 bar (10,000 psi) and is indicated by an audible

“pop.”

3. After achieving pressure relief, the ram automatically

returns to the start position and the nibs retract.

4. Complete the number of crimps specified by the

connector manufacturer.

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

CK06AT and CK06ATC CrimpingTools

#4 to 4/0: 1 crimp

250 to 500: 2 crimps

* Use the number of crimps listed below instead

of the number provided with the connector:

CONNECTOR BARREL ANDERSON BLACKBURN®BURNDY ILSCO PANDUIT T&B PENN-UNION NUMBER

TYPE TYPE OF CRIMPS

COPPER SHORT VHSS CSP YS-L CT SCSS/SCS 54506–54518 BCU

SPLICES

LONG VHS CU YS CTL SCL/SCH 54806–54818 BBCU

COPPER SHORT VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54106–54118 BLU

LUGS YA/YA-L-TC/YA-L-2TC LCD 54206–54286

LONG VHCL CTL-L/LCN YA-2N CRA-L/CRB-L LCB/LCC 54906BE–54919BE BBLU

CRA-2L/CRB-2L 54854BE–54876BE

95R7

Connector Selection

Tool Range: Copper — #4 AWG to 500 kcmil

This tool is ULC and UL classified for use with the following connector brands:

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

CK06AT and CK06ATC 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 nibs for wear or damage such as cracks,

gouges, or chips.

2. Inspect the crimping tool for damage or leaks.

Return a damaged or leaking crimping tool to an

authorized Greenlee service center.

After Each Use

1. Wipe all tool surfaces clean with a damp cloth and

mild detergent.

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

carrying case. Store in a cool, dry place.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

Annually or Every 10,000 Crimps

1. Change the hydraulic oil.

2. Return 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.

2. Remove the tank housing cover.

3. Point the cutting head downward and remove the oil

plug. Add oil if necessary.

4. Replace the oil plug and the tank housing cover.

Secure with screws.

Recommended Hydraulic Oils

AVIA®HVI 15

Shell Tellus T 15

Mobil®DTE 11M

NUTO®H 15

Periodic Pressure ReliefValve Check

Test the crimping tool periodically to ensure that the

pressure relief valve activates at the proper pressure.

Testing the Crimping Tool

1. Center a test slug between the nibs.

2. Pull the trigger to advance the nibs. Hold the trigger

down until the pressure relief valve activates.

3. After achieving pressure relief, the ram automatically

returns to the start position and the nibs retract.

4. Evaluate the test slug as follows:

• If the test slug does not fit into GO slot, the pres-

sure relief valve is set too high. Send the crimping

tool to an authorized Greenlee service center.

•If the test slug fits into the GO slot, the pressure

relief valve is set correctly.

•If the test slug fits into the NO GO slot, the pres-

sure relief valve is set too low. Send the crimping

tool to an authorized Greenlee service center.

NO GO

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

CK06AT and CK06ATC 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.

Ram does not advance Oil level is low. Check oil level. Refill reservoir.

completely.

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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