Greenlee GATOR CK1230 User manual

INSTRUCTION MANUAL
999 4498.7 © 2004 Greenlee Textron Inc. IM 1507 REV 2 5/04
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR®
CK1230 and CK1230C
Crimping Tools
120 Volt and 230 Volt
Serialnummer

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1230 and CK1230C CrimpingTools
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.
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
Die Selection .................................................................. 8
Connector Selection.......................................................8
Maintenance...................................................................9
Periodic Pressure Relief Valve Check ...........................9
Troubleshooting ...........................................................10
Disassembly.................................................................11
Assembly......................................................................12
Illustrations and Parts List ......................................13–18
Description
The CK1230 Hydraulic Crimping Tool is a hand-held,
self-contained tool intended to crimp aluminum and
copper connectors onto electrical cable.
The CK1230C has a PVC-covered crimping 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:
CK123011 120 Volt Crimping Tool
CK1230C11 120 Volt Crimping Tool
with PVC-covered Head
CK123022 230 Volt Crimping Tool
CK1230C22 230 Volt Crimping 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
CK1230 and CK1230C CrimpingTools
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
CK1230 and CK1230C CrimpingTools
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 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.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1230 and CK1230C CrimpingTools
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 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.
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.