ABB H-CK 240 User manual

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Operating Instructions
HYDRAULIC COMPRESSION TOOL
Catalog Number: H-CK 240
TA04922 B Page 1 of 7
Page
1.0 GENERAL INFORMATION..................... 2
1.1 Warnings & Safety Rules ...................... 2
1.2 Features............................................... 2
1.3 Specifications....................................... 2
2.0 PARTS..................................................... 3
2.1
Hydraulic Compression Tool (H-CK 240) ... 3
3.0 OPERATING INSTRUCTIONS ............... 4
3.1
Compression Operation ......................... 4
3.2
Maintenance & Inspection ...................... 4
Page
3.3 Troubleshooting.................................... 5
4.0
IMPORTANT OPERATING PRECAUTIONS ........ 5
4.1
Precautions for Compression Tool ................... 5
5.0 PARTS BREAKDOWN ........................... 6
5.1 Parts Diagram ...................................... 6
5.2 Parts List.............................................. 7
TABLE OF CONTENTS

IMPORTANT: Read and understand all of the
instructions and safety information in this manual
before operating or servicing this tool.
1.0 GENERAL INFORMATION
IN ORDER TO OBTAIN WARRANTY SERVICE
YOU MUST REGISTER YOUR PRODUCT BY
LOGGING IN ON www.tnb.com/toolregistration.
FAILURE TO REGISTER YOUR PRODUCT VOIDS
ALL WARRANTIES.
TA04922 B Page 2 of 7
SPECIFICATIONS
HYDRAULIC COMPRESSION TOOL:
H-CK 240
Dimensions: 480 mm L
Weight: 2.8 kg
Capacities: 6-240 mm
2
Output: 52 kN
1.3
FEATURES
1.2
• Manually operated hydraulic compression tool.
• Two stage rapid advance hydraulics.
WARNINGS
1. BE FAMILIAR WITH YOUR TOOL.
Read the instruction manual. Become aware of its
proper usage as well as the potential hazards.
2. NEVER ATTEMPT TO MAKE A COMPRESSION ON A
"HOT" LINE. HIGH VOLTAGE!
• Never assume the power is OFF! Determine
beforehand if any electrical hazards could exist when
making a connection to a line or wire.
• Tools are NOT insulated for use on or near energized
conductors. Use of these tools near energized
conductors may lead to electrical shock, causing
severe injury or death. DO NOT use these tools near
energized conductors without adequately protecting
operator and surroundings.
3. KEEP FINGERS AND OTHER BODY PARTS AWAY
FROM COMPRESSION DIES & MOVING PARTS.
Pinch point hazard. Compression Dies at high force can
cause severe personal injury. Keep all body parts away
from moving parts of the tool during operation.
4. WEAR ALL REQUIRED PERSONAL PROTECTIVE
EQUIPMENT.
5. DO NOT DISPOSE OF TOOL OR BATTERY AS
RESIDUAL WASTE. TOOL CONTAINS HYDRAULIC
OIL, AND OTHER COMPONENTS WHICH MUST BE
DISPOSED OF SEPARATELY ACCORDING TO
LOCAL ENVIRONMENTAL STANDARDS.
SAFETY RULES
1. KEEP WORK AREA CLEAN AND WELL LIGHTED.
Poor lighting and cluttered areas invite accidents.
2. MAINTAIN TOOL WITH CARE. Keep tool in good
condition at all times. Keep it clean for best and safest
performance.
3. DON'T OVER-REACH. Keep proper footing and
balance at all times.
4. NEVER OPERATE TOOL WITHOUT CRIMPING DIES
INSTALLED. Ensure connector material is inserted
between dies before compression.
WARNINGS & SAFETY RULES
1.1
1 2 3
4 4 4 5

2.0 PARTS
TA04922 B Page 3 of 7
HYDRAULIC COMPRESSION TOOL (H-CK 240)
2.1
C-HEAD
Latch
Ram
Release Pump Handle
Body Handle

3.0 OPERATING INSTRUCTIONS
FIGURE 1
Lift Latch
FIGURE 2
Die Retaining Screw
Die Retaining
Screw
C-Head Ram
2
1
6 Ton Series Dies
To close, lift the C-Head
until it is securely engages
to the Latch.
FIGURE 3
Latch Engaged
COMPRESSION OPERATION
3.1
WARNING
Pinch point hazard. Compression Dies at high
force can cause severe personal injury. Keep
all body parts away from moving parts of the
tool during operation.
1. Retract the Ram fully by pressing the release (2.1).
2. Open the tool head by lifting the Latch (Figure 1).
3.
Select the appropriate size dies for the connector being used.
4. Loosen the two Die Retaining Screws. Insert one die half into the C-head
and then insert the other half of the die into the Ram (Figure 2). Tighten the Die Retaining Screws.
5. Close by lifting the C-Head until it is securely engaged to the Latch (Figure 3).
6. Place connector between the dies. Operate pump handle and advance the Ram (2.1) so the connector is held lightly
between the dies. Do not deform the connector.
7. Insert the conductor into the connector.
8. Continue operating pump handle until the compression is complete. The tool has a built in bypass cartridge which
automatically activates when full pressure is reached. There will be a noticeable decrease in handle force at full pressure
indicating a complete compression.
9. Press the release (2.1) to retract the ram. The ram continues to retract while the release button is pressed. The ram stops
when it is fully retracted.
10. Remove the compressed connector from the tool.
MAINTENANCE & INSPECTION
3.2
1. To ensure smooth operation and prevent rust, store the tool in a cool dry area. Ensure that moving parts are lubricated
regularly.
2. When the plastic housing becomes dirty, clean it with a soft soaped cloth.
3. Dust, sand, and dirt impact the operation, performance and durability of any hydraulic device. After each use, the tool should
be wiped with a clean cloth taking care to remove any residue, especially close to the movable parts.
TA04922 B Page 4 of 7

TROUBLESHOOTING
3.3
Problem Cause Solution
The ram will not advance.
Air in hydraulic system.
Insufcient hydraulic oil.
Hold the tool with head towards the oor to
allow air to rise towards top of oil bladder.
Defective hydraulic circuit. Consult tool service.
The ram will not retract
Tool did not complete a full cycle and
bypass.
Operate pump handle and allow tool to reach
full pressure and bypass, or depress release
to retract the ram.
The connector is jammed in compression
dies.
Depress and hold release button while prying
compression dies apart.
Remove body handle and check on
reservoir for proper or level. The oil should
be at the top of the reservoir when the cap
is removed. Ram should be fully retracted
before removing cap.
The release button is bent or misaligned. Consult tool service.
TA04922 B Page 5 of 7
4.0 IMPORTANT OPERATING PRECAUTIONS
4.1 PRECAUTIONS FOR COMPRESSION TOOL
1. Select the appropriate dies for the connector and conductor to be compressed. Incorrect combinations result in inferior
connections between the connector and conductor and are an electrical hazard.
2. Never operate the tool without dies installed.
3. Always point the tool away from other people.
4. If the tool is stored for an extended period at a temperature of less than 25º F (-5º C), the tool should be allowed to return to
room temperature to ensure smooth operation. Use the tool only after it has been at room temperature for 1 hour.
5. Do not drop the tool. Dropping the tool may damage the hydraulic circuit and cause malfunctions.
6.
Keep the head and ram clean and free of debris. Solvents can be used to clean the head but should not be used on the
plastic body. Use soap & water to clean the body.

TA04922 B Page 6 of 7
H-CK 240 PARTS DIAGRAM
5.1
5.0 PARTS BREAKDOWN

H-CK 240 PARTS LIST
5.2
Pos. Item No. Description Pcs.
1
2
3
4
5
6
7
8
9
10*
11
12
13
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
1
1
1
1
1
1
2
1
1
2
4
2
4
1
2
1
1
1
2
1
1
1
1
1
2
2
2
1
2
1
1
1
1
1
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
64
65
67
68
69
70
71
1
1
1
1
1
1
1
1
1
1
1
3
3
2
4
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
4
07585109
07123303
07123243
07567154
07136120
07351111
07530109
07358327
07079124
07081123
07535131
07277122
07358239
07535152
07506101
07277123
07358185
07535112
07358328
07358201
07525146
07525152
07472155
07386141
07358329
07358241
07725102
07203120
07198122
07369112
07066130
07066129
07198002
07472137
Valve Screw
Spring
Spring
Valve Case
Filter
Oil Reservoir
Plug
O-Ring
Seal Ring
Seal Packing
Backup Ring
Ball
O-Ring
Backup Ring
Steel Ball
Ball
O-Ring
Backup Ring
O-Ring
O-Ring
Plug
Plug
Cerclip
Ring
O-Ring
O-Ring
Magnet
Handle Pipe
Handle
Pump Lever
Pin
Pin
Handle
Circlip
07069002
07600001
07652003
07040001
07123008
07123009
07123007
07123219
07212003
Accessory
07606001
07157001
07105002
07452243
07452021
07452020
07452022
07452023
07452789
07267018
07398002
07175020
07371111
07546103
07585111
07123302
07127110
07565103
07452354
07123304
07585110
07123305
07570133
07066126
Hanger
Lock
Cylinder Head
Plug
Spring
Spring
Spring
Spring
Holder
Crimping Die
Retaining Screw
Bush
Pin
Screw
Screw
Screw
Screw
Screw
Screw
Piston
Spring
Housing
Piston
Relief Valve
Valve Screw
Spring
Holder
Valve Spring
Screw
Spring
Valve Screw
Spring
Lever
Pin
Pos. Item No. Description Pcs.
TA04922 B Page 7 of 7
For Parts or Service, contact Thomas & Betts Tool Service Center at 1-800-284-TOOL (8665)
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
ABB
8 Bvd Millenium,
B-7110 La Louviere,
Belgium
© 2016 ABB. All Rights Reserved.