Textron Greenlee HK12ID Bedienungsanleitung

INSTRUCTION MANUAL

HK12ID

Dieless Crimping Tool

Español............... 11

Français.............. 21

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

HK12ID Dieless Crimping Tool

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

Description

The HK12ID Hydraulic Crimping Tool is a hand-held,

self-contained, dieless crimping tool intended to crimp

aluminum and copper connectors onto electrical cable.

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 manual is intended to familiarize all personnel with

the safe operation and maintenance procedures for the

following Greenlee tool:

HK12ID Dieless Crimping Tool

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 Textron Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

Blackburn is a registered trademark of Thomas & Betts.

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....................................................................6–7

Preparation ................................................................ 6

Crimping .................................................................6–7

cUL and UL Classied Crimps................................... 7

Connector Table......................................................... 7

Maintenance...............................................................8–9

Schedule.................................................................... 8

Periodic Pressure Relief Valve Check.....................8–9

Verify Crimping Distance ........................................... 9

Español...................................................................11–19

Français..................................................................21–29

Illustration and Parts List........................................30–31

HK12ID Dieless Crimping Tool

Greenlee / A Textron Company 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 electri-

cal lines, use proper personal protec-

tive 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 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, gangrene,

or death. If you are injured by escap-

ing oil, seek medical attention

immediately.

HK12ID Dieless Crimping Tool

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

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.

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

operation. 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.

HK12ID Dieless Crimping Tool

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

Identiﬁcation

1 6

Speciﬁcations

Crimping Tool

Length ............................................................................................656.8 mm (25.9")

Height..................................................................................................150 mm (5.9")

Mass/Weight ......................................................................................6.9 kg (15.2 lb)

Crimping Capacities

Crimping Range

Aluminum............................................................................ 6 AWG to 1000 kcmil

Copper................................................................................ 4 AWG to 1000 kcmil

HK12ID

1. Indenter

2. Crimping Head

3. Latch (for opening head)

4. Handle

5. Handle with Reservoir

6. Serial Number (located on

main body beneath rubber cover)

HK12ID Dieless Crimping Tool

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

Operation

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.

Electric shock hazard:

This tool is not insulated. When using

this unit on or near energized electri-

cal lines, use proper personal protec-

tive 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 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, gangrene,

or death. If you are injured by escap-

ing oil, seek medical attention

immediately.

Pinch points:

Keep hands away from the crimping

tool head when crimping.

Failure to observe this warning could

result in severe injury or death.

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.

For a cUL or UL classied crimp, refer to the

Connector Table in this instruction manual.

Preparation

1. Select a proper size and type of connector to

correspond with the wire or cable.

2. Strip the cable to an appropriate length. Follow the

connector manufacturer’s instructions.

Note: Apply an oxide inhibitor, if required.

Refer to the connector manufacturer’s instructions.

Crimping

1. Insert the cable fully into the connector.

2. Place the connector into the V of the crimping head,

as shown below.

Connector

3. If open, close the crimping head. Make sure the

head and latch are fully engaged.

HK12ID Dieless Crimping Tool

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

Operation (cont’d)

Crimping (cont’d)

4. For a UL or cUL classied crimp, complete the

number of crimps specied in the Connector Table

below.

5. For a single crimp, position the connector so the

crimp will be located at the center of the barrel.

For a double crimp, position the connector so two

crimps will be evenly spaced between the connec-

tor marks.

6. Pump the handle to advance the indenter. Continue

to pump the handle until the pressure relief valve

activates.

Note: Pressure relief is indicated by an audible

“pop”. The handle load will also drop suddenly to

indicate a complete crimp.

7. Retract the indenter by twisting the pump handle

clockwise in the open position and closing the

handle to activate the release valve. Continue to

hold the pump handle closed to completely retract

the indenter.

8. Lift the latch to open the crimping head and remove

the connector.

9. After completing the last crimp on an aluminum

connector, wipe off the excess oxide inhibitor.

Note: if it is necessary to retract the indenter before a

crimp cycle is complete, raise the pump handle, twist

clockwise, and close the handle to activate the release

valve and retract the indenter.

cUL and UL Classiﬁed Crimps

Crimps made with the Greenlee HK12ID Dieless Crimping Tool are cUL and UL classied on standard

concentric, compressed, or compact stranded copper and aluminum cable with the connectors listed

here. Refer to the Connector Table for the brand names and model numbers of appropriate connectors

and the number of crimps required.

Connector Table

Copper Connector Type Anderson Blackburn®Burndy ILSCO Panduit T & B Penn-

Union Tyco (AMP)

Copper Splices VHSS

VHS

CSP

YS-L

CTL

SCSS

SCS

SCL, SCH

54506 to 54528

54806 to 54828

BCU

BBCU —

Copper Lugs VHCS

VHCL

CTL

CTL-L

LCN

YA, YA-L, YA-2L

YA-2LN, YA-2N

YA-L-TC, YA-L-2TC

YA-2TC, YAZ

YAZ-2N, YAZ-2TC

CLN, CLW, CSW

CRA, CRB, CRC

CRA-L, CRB-L

CRA-2L

CRB-2L

CRC-2L

LCAS

LCA

LCB

LCD, LCC

LCAN

54106 to 54128

54206 to 54228

54906BE to 54928BE

54854BE to 54882BE

BLU

BBLU

1099898-2 to

1-1099898-5,

1099899-2 to

1-1099899-9,

1099939-1 to

1-1099939-5

Number of

Crimps*

Copper Cable Size:

4 AWG to 1000 kcmil 1 1 1 1 1 1 1 1

Aluminum Connector Type Anderson Blackburn®Burndy ILSCO Panduit T & B Penn-

Union

Dual-Rated Aluminum Splices VACS ASP YS-A AS, ASN SA 60507 to 60584 PIK

BCUA

Dual-Rated Aluminum Lugs VACL ATL YA-A

YA-A-TN

ACL, ACN

2ACL, 2ACN

ALNS, ALNN

ALND

LAA

LAB

60106 to 60184

60230 to 60284 BLUA

Number of

Crimps*

Cable Size: 6 AWG to 500 kcmil 1 1 1 1 1 1 1

Cable Size: 600 kcmil to 800 kcmil 2 1 1 1 2 1 1

Cable Size: 1000 kcmil 2 2 2 2 2 2 2

* When crimping with the HK12ID crimping tool, use the number of crimps listed in this table

instead of the number provided with the connector.

HK12ID Dieless Crimping Tool

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

Maintenance

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from ying

debris or hydraulic oil.

Schedule

Each Operating Day

Before use:

1. Inspect indenter and head for wear or damage such

as cracks, gouges, or chips.

2. Inspect the tool for damage or leaks. If damage is

detected, return the tool to a Greenlee Authorized

Service Center for inspection.

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, gangrene,

or death. If you are injured by escap-

ing oil, seek medical attention

immediately.

After use:

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

mild detergent.

2. Place tool in the carrying case. Store in a cool, dry

place.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

3. Oil the pin joints and metal surfaces that slide.

Annually or After 10,000 Cycles

1. Change the hydraulic oil.

2. Return the tool to a Greenlee Authorized Service

Center for inspection.

Periodic Pressure Relief Valve Check

Pinch points:

Keep hands away from the crimping

tool head when crimping.

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 50013408 test meter, 50065750 sensor,

and 52024054 adapter (purchased separately).

1. Install the Greenlee 50065750 sensor into the

52024054 adapter, as shown below.

52024054

Adapter

50065750

Sensor

HK12ID Dieless Crimping Tool

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

Maintenance (cont’d)

Periodic Pressure Relief Valve Check

(cont’d)

2. Lift the latch to open the crimping head and install

the adapter between the indenter and crimp head.

Position the round end of the adapter against the

indenter and close the crimp head against the

V-surfaces on the adapter, as shown below.

Check that the head and latch are fully engaged.

3. Connect the sensor cable to the test meter and cali-

brate the sensor per operating instructions provided

with the 50013408 test meter.

4. Pump the handle to advance the indenter until the

pressure relief valve activates. The display on the

test meter should show a force of 107.8 to 110.8 kN

(24,250 to 24,925 lb). If the force reading is outside

this range, send the crimping tool to an authorized

service center for adjustment.

Relief valve adjustments must be done by an autho-

rized service center.

Verify Crimping Distance

The crimping distance on this tool is set at the factory

to a precise dimension to insure a certied crimp. The

crimping distance may require resetting if the indenter,

crimping head, or other components are replaced on

the tool. Follow the procedure below to verify and reset

the crimping distance.

1. Close the crimping head and check that latch and

head are fully engaged.

2. Pump the handle to advance the indenter. Continue

to pump the handle until the indenter is a full stroke

and the handle force is noticeably greater.

3. Measure the distance between the bottom of the

indenter and the head as shown below. The dis-

tance should measure 4.953 mm to 5.207 mm

(0.195" to 0.205"). If the distance is outside this

range, rermove the set screw (72) and indenter (40).

• To increase distance, remove a spacer (41, 42).

• To decrease distance, add a spacer (41, 42).

5.207 mm (0.205")

4.953 mm (0.195")

4. Install the indenter (40) and secure set screw (72).

HK12ID Dieless Crimping Tool

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

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