Greenlee GATOR CK22GL Bedienungsanleitung

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

GATOR®

CK22GL Crimping Tool

120 Volt and 230 Volt

Serialnummer

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

CK22GL CrimpingTool

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.

Blackburn is a registered trademark of Thomas & Betts.

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 ...................................................................7–8

Dies and Connectors......................................................9

Maintenance.................................................................10

Troubleshooting ...........................................................11

Disassembly.................................................................12

Assembly......................................................................13

Illustrations .............................................................14–16

Parts List ................................................................17–19

Description

The CK22GL Hydraulic Crimping Tool is a hand-held,

self-contained tool intended to crimp copper cable with

KA22-type, KC22-type, and W-type dies.

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:

CK22GL11 120 Volt Crimping Tool

CK22GL22 230 Volt Crimping Tool

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

CK22GL CrimpingTool

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

CK22GL CrimpingTool

IMPORTANT SAFETY INFORMATION

Pinch points:

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.

An incomplete crimp can cause a fire.

•Use proper die, connector, and cable combina-

tions. Improper combinations can result in an

incomplete crimp.

• Use only W-type dies on aluminum connectors or

aluminum wire. Mismatched components can

result in an incomplete 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.

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

CK22GL CrimpingTool

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 and dies 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.

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.

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

CK22GL CrimpingTool

Identification

Specifications

CK22GL

1. Housing

2. Retract Button

3. Power Cord

4. Trigger

5. Locking Flange

6. Die Release Buttons

7. W-type Die Detents

8. Crimping Dies

9. Crimping Head

10. Oil Reservoir

11. Oil Plug

Crimping Tool

Length........................................................................................... 314 mm (12-3/8")

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

Height ........................................................................................... 298 mm (11-3/4")

Mass/Weight ....................................................................................... 3.8 kg (8.4 lb)

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

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

Motor Voltage

CK22GL11........................................................................ 120 VAC, 60 Hz, 2.1 A

CK22GL22........................................................................ 230 VAC, 50 Hz, 1.1 A

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

Crimping Capacities

Crimping Range

Copper.................................................................................. 8 AWG to 600 kcmil

Aluminum.............................................................................. 8 AWG to 350 kcmil

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

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

CK22GL CrimpingTool

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.

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.

Installing K22, KA22, and KC22-type Dies

1. Select the proper dies for the intended crimp.

2. Push the die release button.

3. Slide the die into the crimping head until it “snaps”

into place.

4. Properly position the second die. Repeat Steps

2 and 3.

Installing W-type Dies

1. Push the die release button.

2. Slide the die adapter (Greenlee part number

500 4292.0) into crimping head until it “snaps”

into place.

Note: The die adapters have the “D

” die profile.

No additional dies are needed if the connector to be

crimped requires a “D

” die.

3. Repeat for the other adapter.

4. Select the proper dies for the intended crimp.

5. Press the locking flange and open the crimping

head.

6. Push the W-type die detent and slide the W-type die

into place.

7. Properly position the second die. Repeat Steps

5 and 6.

•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.

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

CK22GL CrimpingTool

Operation (cont’d)

Crimping Cable

1. Press the locking flange and open the crimping

head.

2. Clean the die seat area.

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

4. Follow the connector manufacturer’s instructions

for appropriate cable strip length and surface

preparation.

5. Insert the properly assembled connector into the

crimping head.

6. Close the crimping head.

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

55 kN (6.2 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 with W-type dies

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.

• Use only W-type dies on aluminum connectors or

aluminum wire. Mismatched components can

result in an incomplete 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.

Pull trigger to crimp

Push to retract ram

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

CK22GL CrimpingTool

Die Selection

Crimps made on copper cable with Greenlee KC22-type dies and the copper connectors listed here are

cUL and UL classified.

Crimps made on copper or aluminum cable with Greenlee KA22-type dies and the dual-rated aluminum 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.

W-type or X-type dies can be used to crimp 8 AWG to 500 kcmil copper and 8 AWG to 4/0 AWG aluminum.

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 54504–54520 BCU A

Splice Long VHS CU YS CTL SCL/SCH 54804–54820 BBCU B

Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54104–54120 BLU A

Copper YA/YA-L-TC/YA-L-2TC LCD 54204–54218

Lugs Long VHCL CTL-L/LCN YA-2N CRA-L/CRB-L LCB/LCC 54930BE–54920BE BBLU B

CRA-2L/CRB-2L 54850BE–54878BE

Catalog UPC Cable Color

Number Number Size Code

KC22-8 03079 8 AWG Red

KC22-6 03080 6 AWG Blue

KC22-4 03081 4 AWG Gray

KC22-2 03082 2 AWG Brown

KC22-1 03083 1 AWG Green

KC22-1/0 03084 1/0 AWG Pink

KC22-2/0 03085 2/0 AWG Black

KC22-3/0 03086 3/0 AWG Orange

KC22-4/0 03087 4/0 AWG Purple

KC22-250 03088 250 kcmil Yellow

KC22-300 03089 300 kcmil White

KC22-350 03090 350 kcmil Red

KC22-400 03091 400 kcmil Blue

KC22-500 03092 500 kcmil Brown

KC22-600 03093 600 kcmil Green

Connector Selection

Tool Range: Copper — 8 AWG to 600 kcmil; Dual-rated Aluminum — 8 AWG to 350 kcmil

When used with KC22-type dies, this tool is cUL and UL classified for use with the following connector brands:

Dies for Copper Connectors Dies for Dual-rated Aluminum Connectors

Catalog UPC Cable

Number Number Size

KA22-8 06744 8 AWG

KA22-6 06745 6 AWG

KA22-4 06746 4 AWG

KA22-2 06747 2 AWG

KA22-1 06749 1 AWG

KA22-1/0 06750 1/0 AWG

KA22-2/0 06751 2/0 AWG

KA22-3/0 06752 3/0 AWG

KA22-4/0 06753 4/0 AWG

KA22-250 06754 250 kcmil

KA22-300 06755 300 kcmil

KA22-350 06756 350 kcmil

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

Type Type Union Crimps*

Dual-rated

Aluminum — VACS ASP YS-A AS SA 60501–60565 PIK C

Splice **

Dual-rated YA-A ACL/ACN LAA/LAB 60101–60166

Aluminum — VACL ATL BLUA C

Lugs YA-ATN 2ACL/2ACN ** 60230–60267

When used with KA22-type dies, this tool is cUL and UL classified for use with the following connector brands:

*Use the number of crimps listed in the last column instead of the number provided with the connector:

95R7

C — 8 to 2 AWG: 2 crimps

1 to 3/0 AWG: 3 crimps

4/0 AWG to 350 kcmil: 4 crimps

B — 8 to 1/0 AWG: 2 crimps

2/0 to 3/0 AWG: 3 crimps

4/0 AWG to 600 kcmil: 4 crimps

A — 8 to 1/0 AWG: 1 crimp

2/0 AWG to 600 kcmil: 2 crimps

** 6 AWG to 350 kcmil

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

CK22GL CrimpingTool

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. Oil the bolt joints.

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

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