ABB H-CK 400 User manual

Operating Instructions
HYDRAULIC COMPRESSION TOOL
Catalog Number: H-CK 400
TA04930 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 400) ..... 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.
TA04930 B Page 2 of 7
SPECIFICATIONS
HYDRAULIC COMPRESSION TOOL:
H-CK 400
Dimensions: 585 mm L
Weight: 6.0 kg
Capacities: 10 - 400 mm
2
Output: 106 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
TA04930 B Page 3 of 7
HYDRAULIC COMPRESSION TOOL (H-CK 400)
2.1
Die Release Pin
Crimping Head
Ram
Release Pin
Pump Handle
Body Handle

3.0 OPERATING INSTRUCTIONS
TA04930 B Page 4 of 7
Die Release Pins
Ram
Crimping
Head
155xxM
Series Dies
FIGURE 1
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 opening the pump handle and rotating it fully
clockwise. Close the pump handle while maintaining its rotated
position to make contact with the release pin on the tool body (2.1).
2.
Select the appropriate size dies for the connector being used.
3. Insert the dies into the crimping head and ram by sliding the dies in
while pressing the die release pins (Figure 1).
4. 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.
5. Insert the conductor into the connector.
6. 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.
7. Retract the Ram according to step 1.
8. 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 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.

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 pin while prying
compression dies apart.
Remove body handle and check on
reservoir for proper oil 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 pin is bent or misaligned. Consult tool service.
TA04930 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 body.
Use soap & water to clean the body.

TA04930 B Page 6 of 7
H-CK 400 PARTS DIAGRAM
5.1
5.0 PARTS BREAKDOWN

H-CK 400 PARTS LIST
5.2
Pos. Item No. Description Pcs.
1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
2
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
78
79
80
81
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
2
2
1
3
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
07358700
07535131
07081123
07168100
07055101
07358239
07123226
07546100
07358201
07358198
07585104
07123227
07277121
07123228
07277122
07175280
07585105
07535122
07358310
07123242
07506100
07452254
07506101
07525124
07138102
07136111
07386126
07358311
07380101
07585218
07129101
07452237
07178100
07358208
07351106
07530109
07203222
07251107
07198114
07725102
O-Ring
Backup Ring
Seal Packing
Screw
Reaction Pin
O-Ring
Spring
Relief Valve
O-Ring
O-Ring
Valve Screw
Spring
Ball
Spring
Ball
Housing
Valve Screw
Backup Ring
O-Ring
Spring
Steel Ball
Screw
Steel Ball
Plug
Filter Housing
Filter
Ring
O-Ring
Spring
Valve Screw
Spring Cap
Screw
Cap
O-Ring
Oil Reservoir
Plug
Handle Pipe Assy
Cap
Handle
Magnet
07452220
07123220
07043100
07093100
07093100
07256100
07273100
07452235
07132102
07162100
07417145
07452236
07256101
07042104
07267118
07093101
07081173
07256102
07535115
07358307
07156100
07398105
07130102
07472138
07472137
07022116
07066114
07524215
07369104
07068117
07256103
07251106
07368100
07093102
07597100
07256104
07369105
07198113
07371103
07079108
Screw
Spring
Blocker
Bolt
Pin
Lock Pin
Head
Screw
Spring Washer
Liner
Washer
Screw
Lock Pin
Lock Pin
Piston
Pin
Seal Packing
Lock Pin
Backup Ring
O-Ring
Pin
Spring
Spring Plate
Snap Ring
Snap Ring
Pin
Pin
Pin
Pump Lever Head
Bush
Lock Pin
Cap
Spring
Pin
Bolt
Lock Pin
Pump Lever
Handle
Piston
Seal Ring
Pos. Item No. Description Pcs.
TA04930 B Page 7 of 7© 2017 ABB Inc. All Rights Reserved.
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 Inc.
8 Bvd Millenium,
B-7110 La Louviere, Belgium