Greenlee CCCX User manual

INSTRUCTION MANUAL
999 4509.6 © 2004 Greenlee Textron Inc. IM 1518 REV 4 6/04
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR™PRO
CCCX and CCCXC Tools
120 Volt and 230 Volt
Serialnummer

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CCCX and CCCXCTools
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 and Kwik Stepper are registered trademarks 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 .................................................................7–15
Crimping .................................................................8–9
Cutting ......................................................................10
Punching.............................................................11–15
Available Adapters .......................................................16
Die Selection ................................................................ 17
Connector Selection.....................................................17
Maintenance.................................................................18
Troubleshooting ...........................................................18
Disassembly.................................................................19
Assembly......................................................................20
Illustrations .............................................................21–23
Parts List ................................................................24–26
Description
The CCCX Tool is a hand-held, self-contained tool
intended to crimp cable, cut cable and threaded rod,
and punch holes with the proper adapters.
The CCCXC has a PVC-covered 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:
CCCX11 120 Volt Tool
CCCXC11 120 Volt Tool
with PVC-covered Head
CCCX22 230 Volt Tool
CCCXC22 230 Volt Tool
with PVC-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
CCCX and CCCXCTools
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 tool in a hazardous
environment. Hazards include
flammable liquids, gases, or other
materials. Using this 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
CCCX and CCCXCTools
IMPORTANT SAFETY INFORMATION
An incomplete crimp can cause a fire.
•Use proper die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
•An audible “pop” indicates that the crimping tool
has achieved a complete crimp. If you do not
hear a “pop,” the crimp is incomplete.
Failure to observe these warnings could result in
severe injury or death.
Pinch points:
Keep hands away from the tool head
when in use.
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
CCCX and CCCXCTools
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, dies, and adapters 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.
• Do not operate tool without adapters. Damage
to the ram, tool head, or accessories may result.
•This tool is not designed for continuous use.
After 30 to 40 cycles, allow the tool to cool for
15 minutes.
•Do not place the tool in a vise. This 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
CCCX and CCCXCTools
IdentificationIdentification
Specifications
CCCX and CCCXC
1. Housing
2. Retract Button
3. Power Cord
4. Trigger
5. Head
6. Latch (for opening head)
7. Adapter Release Buttons
Tool
Length...............................................................................................371 mm (14.6")
Width........................................................................................................76 mm (3")
Height ..................................................................................................279 mm (11")
Mass/Weight ..................................................................................... 4.02 kg (8.9 lb)
Sound Level...........................................................................< 75 dB (A) at 1 meter
Vibration.................................................................................................... < 2.5 m/s2
Motor Voltage
CCCX11 ............................................................................120 VAC, 60 Hz, 2.1 A
CCCX22 ............................................................................230 VAC, 50 Hz, 1.1 A
Hydraulic Oil ....................................................50 ml (0.1 pint) of Shell Tellus®T 15
Crimping Tool
Maximum Crimping Cable Size ................... 600 kcmil copper; 350 kcmil aluminum
Crimping Time ..........................................................................................4 seconds
Cutting Tool
Maximum Cutting.................................... 40 mm (1-1/2") kcmil aluminum or copper
2
4
1
3
67
5

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CCCX and CCCXCTools
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.
• Do not operate tool without adapters. Damage
to the ram, tool head, or accessories may result.
•This tool is not designed for continuous use.
After 30 to 40 cycles, allow the tool to cool for
15 minutes.
•Do not place the tool in a vise. This 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 tool head
when in use.
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
CCCX and CCCXCTools
Operation (cont’d)
Crimping
Setup
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Select the appropriate set of dies. Use the
table provided on this page to select the
corresponding adapter set.
4. Install the adapters and dies—one set in each
groove. If either the adapters or dies have W-type
tabs, lock them in place with the W-type detents.
Important: W-type dies must be locked into place
or the die detents will be damaged.
5. Visually check the dies to ensure that they are
aligned correctly so that they will complete the
crimping operation.
6. Close the tool head.
Dies Adapter Set
Greenlee K22, KA22, KC22-type UA22
Greenlee W-type UAW
Kearney “OD” UAK
Thomas & Betts “6TON” UAK
D3Profile UAW
Blackburn®“O” UAK
Huskie “HT” UAK
FCI Burndy “W” UAW
Huskie “HT-58” UAW
Ilsco “ND-60” UAW
Izumi “N58” UAW
Panduit “CD-2001” UAW
Accessory Table
W-type
W-type Detents: Press
and slide the adapter
and/or die into place.
Release to lock.
K22-type
Kearney
Important: W-type dies
must be locked into
place or the die detents
will be damaged.

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CCCX and CCCXCTools
1. Press the latch and open the tool 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 tool
head.
6. Close the tool head.
An incomplete crimp can cause a fire.
•Use proper die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
•An audible “pop” indicates that the crimping tool
has achieved a complete crimp. If you do not
hear a “pop,” the crimp is incomplete.
Failure to observe these warnings 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.
Operation (cont’d)
Crimping (cont’d)
Crimping Procedure
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
60 kN (6.7 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 on an aluminum
connector, wipe off the excess oxide inhibitor.
CRIMPING DIRECTION
1ST COMPRESSION
CRIMPING DIRECTION
SIDE A
CRIMPING DIRECTION
SIDE B
1ST COMPRESSION
SIDE A
1ST COMPRESSION
SIDE B

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CCCX and CCCXCTools
Operation (cont’d)
Cutting
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.
Electric shock hazard:
This tool is not insulated. When using
this unit as a cable cutter on or near
energized electrical lines, use proper
personal protective equipment.
Failure to observe this warning could
result in severe injury or death.
Setup
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Select the appropriate set of blades, using the
table provided on this page.
4. Install one blade in each groove. If the blades have
W-type tabs, lock them in place with the W-type
detents.
Important: W-type dies must be locked into place
or the die detents will be damaged.
5. Visually check the blades to ensure that they are
aligned correctly so that they will complete the
butting operation.
6. Close the tool head.
Setup for Din Rail Cutters
1. Install both blades in the movable head.
2. Close the head.
3. Slide one blade over until it engages in the W-type
detents.
Cutting Procedure
1. Press the latch and open the tool head.
2. Position the item to be cut in the tool head.
3. Close the tool head.
4. Pull the trigger to cut the item.
5. Release the trigger when the cut is complete.
6. The ram returns automatically.
Accessory Table
Task Blade
Copper and aluminum UC26
26 mm (1.00") max.
Copper and aluminum UC40
40 mm (1.56") max.
ACSR
Copperweld
ACAR
Guy strand
EHS guy strand UCACSR
Ground rod
Anchor rod
Soft bolts
Rebar
Threaded rod Threaded rod
DIN rail DIN rail
W-type Detents:
Press and slide the
adapter and/or die
into place.
Release to lock.
Important: W-type dies must be locked into
place or the die detents will be damaged.