Greenlee GATOR CK1240 User manual

INSTRUCTION MANUAL
999 4499.5 © 2004 Greenlee Textron Inc. IM 1508 REV 2 5/04
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR®
CK1240 and CK1240C
Crimping Tools
120 Volt and 230 Volt
Serialnummer

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C 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 CK1240 Hydraulic Crimping Tool is a hand-held,
self-contained tool intended to crimp aluminum and
copper connectors onto electrical cable.
The CK1240C 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:
CK124011 120 Volt Crimping Tool
CK1240C11 120 Volt Crimping Tool
with PVC-covered Head
CK124022 230 Volt Crimping Tool
CK1240C22 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
CK1240 and CK1240C 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
CK1240 and CK1240C 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.
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.
Pinch points:
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C 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.

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Identification
Specifications
CK1240 and CK1240C
1. Housing
2. Retract Button
3. Power Cord
4. Trigger
5. Die Release Buttons
Crimping Tool
Length...............................................................................................396 mm (15.6")
Width...................................................................................................80 mm (3.16")
Height ..................................................................................................279 mm (11")
Mass/Weight ..................................................................................... 6.3 kg (13.9 lb)
Sound Level...........................................................................< 75 dB (A) at 1 meter
Vibration.................................................................................................... < 2.5 m/s2
Motor Voltage
CK124011 and CK1240C11.............................................120 VAC, 60 Hz, 2.1 A
CK124022 and CK1240C22.............................................230 VAC, 50 Hz, 1.1 A
Hydraulic Oil ....................................................50 ml (0.1 pint) of Shell Tellus®T 15
Recommended Operating Temperature Range.... –15 °C (5 °F) through 50 °C (120 °F)
Crimping Capacities
Crimping Range........................................................................ 8 AWG to 750 kcmil
Crimping Force ...............................................................................106 kN (12 tons)
2
5
4
1
3

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Operation
1. Clean the die seat area.
2. Install the proper size and type of crimping dies.
3. Press the release button on the C-head and slide
one of the die halves into the jaw. Release the
button and slide the die half until the retainer snaps
and locks the die into place.
4. Press the release button on the ram body (located in
the cutout) and slide the other die half in. Release
the button and slide the die half until the retainer
snaps and locks the die into place.
5. Follow the connector manufacturer’s instructions
for appropriate cable strip length and surface
preparation.
6. Insert cable fully into connector and center the
connector between the dies.
CRIMPING DIRECTION
1ST COMPRESSION
CRIMPING DIRECTION
SIDE A
CRIMPING DIRECTION
SIDE B
1ST COMPRESSION
SIDE A
1ST COMPRESSION
SIDE B
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
106 kN (12 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. When using KC12-type dies, complete the number
of crimps listed on the “Connector Selection” chart in
this manual. For other dies, complete the number of
crimps specified by the 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.
Pinch points:
Keep hands away from the crimping
tool head when crimping.
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
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.
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.

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Die Selection
Crimps made on copper cable with Greenlee
KC12-type dies and the copper connectors
listed here are cUL and UL classified.
Refer to “Connector Selection” for brand names
and model numbers of appropriate lugs as well
as crimping instructions.
Connector Barrel Anderson Blackburn®FCI Burndy Ilsco Panduit T&B Penn- No. of
Type Type Union Crimps*
Copper Short VHSS CSP YS-L CT SCSS/SCS 54504–54523-TB BCU
Splice Long VHS CU YS CTL SCL/SCH 54804–54823 BBCU
Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54104–54123-TB BLU
Copper YA/YA-L-TC/YA-L-2TC CRC LCD/LCAN 54204–54223
Lugs YA/YAZ CRA-L/CRB-L 54930BE–54923BE
Long VHCL CTL-L/LCN YA-2N/YA-2TC CRA-2L/CRB-2L LCB/LCC 54850BE–54880BE BBLU
YAZ-2N/YAZ-2TC CRC-2L
Catalog UPC Cable Color No. of
Number Number Size Code Crimps
KC12-8 10996 8 AWG Red 1
KC12-6 10997 6 AWG Blue 1
KC12-4 10998 4 AWG Gray 1
KC12-2 10999 2 AWG Brown 1
KC12-1 11003 1 AWG Green 1
KC12-1/0 11004 1/0 AWG Pink 1
KC12-2/0 11007 2/0 AWG Black 1
KC12-3/0 11010 3/0 AWG Orange 1
KC12-4/0 11011 4/0 AWG Purple 1
KC12-250 11012 250 kcmil Yellow 1
KC12-300 11013 300 kcmil White 2
KC12-350 11014 350 kcmil Red 2
KC12-400 11015 400 kcmil Blue 2
KC12-500 11016 500 kcmil Brown 2
KC12-600 11018 600 kcmil Green 2
KC12-750 11020 750 kcmil Black 2
Connector Selection
Tool Range: 8 AWG to 750 kcmil
When used with KC12-type dies, this tool is cUL and UL classified for use with the following connector brands:
Dies for Copper Connectors
*Use the number of crimps listed in this column instead of the number provided with the connector.
95R7
8 AWG to
250 kcmil:
1 crimp
300 to
750 kcmil:
2 crimps

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Maintenance
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.
Daily
Before use:
1. Inspect dies for wear or damage, such as cracks,
gouges, or chips.
2. Inspect the crimping tool for damage or leaks.
After use:
1. Use a damp cloth and mild detergent to clean the
housing. Allow the housing to dry.
2. Fully retract the ram. Place the crimping tool in the
carrying case and store in a cool, dry place.
Monthly
1. Thoroughly clean all surfaces.
2. Check the oil level.
3. Perform the “Periodic Pressure Relief Valve Check.”
Annually or After 10,000 Crimps
1. Replace the hydraulic oil.
2. Send the tool to an authorized Greenlee service
center for inspection.
Checking the Oil Level
1. Remove the two screws that retain the tank housing
cover. Remove the tank housing cover.
2. Point the crimping head downward and remove the
oil reservoir plug. Fill reservoir if necessary.
3. Replace the oil plug and tank housing cover.
Recommended Hydraulic Oils
AVIA®HVI 15
Shell Tellus T 15
Mobil®DTE 11M
NUTO®H 15
Periodic Pressure ReliefValve Check
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 model 35887 Load Cell (purchased
separately).
1. Insert the test die into the tool (refer to steps 3 and 4
under “Operation” in this manual). Position the load
cell so that the load cell piston is centered between
the two test dies.
2. Press the trigger until the crimping tool achieves
pressure relief and note the position of the needle
when the pressure relief is achieved. The needle
should indicate the “12T” range; if the needle is
outside of this range, send the crimping tool to an
authorized service center for adjustment.
Note: If some other type of load cell is used, the ratio
between the area of the tool and the area of the load
cell may be different. The appropriate corresponding
pressure range depends upon this ratio.
Relief valve adjustments must be done by an
authorized service center.
Pinch points:
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Troubleshooting
Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.
of tool.
Tool components worn or damaged. Return tool to an authorized
Greenlee service center.
Dies stop during operation. Oil level is low. Check oil level. Refill reservoir.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately
10 seconds.
Tool loses oil. Damaged internal seal. Return tool to an authorized
Greenlee service center.
Oil plug not installed properly. Refill reservoir and replace plug.
Problem Probable Cause Probable Remedy

Greenlee / A Textron Company 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Disassembly
Main Components
1. Loosen the screw (28). Remove the screw (35) and
stop (36).
2. Unscrew and remove the head assembly.
3. Remove the piston (8). Replace the piston O-ring (6)
and piston backup ring (7).
4. Unscrew two tank cover screws (52) and remove the
tank cover.
5. Remove the hydraulic reservoir plug (76) and drain
the hydraulic fluid.
6. Reinstall the plug.
7. Remove the remaining housing screws (52).
8. Remove the housing half.
9. Remove the switch cover (51) and spring (56).
10. Lift the pump/motor assembly and circuit card from
the housing half.
11. Slide a plastic bag over the circuit card and elec-
tronic subassemblies. Tape the bag shut to protect
the subassemblies from hydraulic oil and other
contamination.
12. Unscrew the shoulder bolt (99) and remove the
release lever (107).
13. Remove screws (108) and separate the gear
housing/motor subassembly from the pump housing.
Pump
1. Use a hooked tool to remove the reservoir O-ring (80).
Gently tug it over the reservoir.
2. Remove the reservoir (74).
3. Remove the pump piston (152).
4. Remove the screw plug (151), washer (153), pump
piston (150), valve stem (156), and spring (155).
Replace the sealing washer (154).
5. Use a piece of tape to mark the side of the relief
that is facing up. (This is a reference point for
reassembly.) Remove the unloading valve by
unscrewing the plug (126).
6. Remove the feeder tube subassembly by unscrew-
ing the feeder tube (78). Replace the oil filter (77).
Remove metal chips from the magnet (82).
7. Remove the threaded bushing (72) and replace the
O-ring (73).
Motor, Gearbox, and Bearing
1. Remove the tamper-proof paper seal (96).
2. Remove two screws (92). Remove the end cap
(102).
3. Apply pressure evenly at three points around the
ball bearing (91) and gently pry the bearing up to
remove it.
4. Remove the eccentric (103), grooved ball bearing
(101), and snap ring (100) subassembly from the
shaft.
5. Remove four screws (93). Remove the mounting
block (109) from the gear housing (94).
6. Use a snap-ring removal tool to remove the snap
ring (100).
7. Unscrew four bolts (not numbered) and hex nuts
(97) from the gear housing (94). Separate the gear
housing from the motor flange (110). Unscrew two
flat head screws (112) to separate the flange from
the motor (90).

Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Motor, Gearbox, and Bearing
1. Install four hex nuts (97) into the motor flange (110).
2. Install two flat head screws (112) into the motor
flange (110) and motor (90). Tighten the screws.
3. Install four screws (not numbered) and hex nuts (97)
into the gear housing (94). Tighten the screws.
4. Install four screws (93) into the mounting block (109)
and gear housing (94). Tighten the screws.
5. Replace the grooved ball bearing (101) and snap
ring (100).
6. Replace the eccentric (103). Use a fiber mallet to tap
the eccentric onto the shaft. Replace the ball bearing
(91).
7. Align the end cap (102). Use a fiber mallet to tap the
cover until it is flush on the mounting block (109).
Install two screws (92).
8. Align the gear housing/motor subassembly so that
the pump piston (152) extends through the mounting
block (109) and makes contact with the grooved
bearing (101). Locate and start the screws (108)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert the pump piston (152) into the pump housing.
2. Insert the seal (122) and unloading valve subassem-
bly into the pump housing. Grasp the needle valve
subassembly by the plug (126) and twist it several
turns clockwise. Stop when the piece of tape is
facing up.
3. Assemble the pump piston (150), valve stem (156),
washer (153), spring (155), and screw plug (151).
Be sure to replace the sealing washer (154). Torque
the screw plug (151) to 102 Nm (75 ft-lb).
4. Install the release lever (107) so that the forked end
engages the unloading valve subassembly between
the pressure relief (126) and the support ring (127).
Install the screw (99) and washer (104).
5. Insert the threaded bushing (79) and feed tube
subassembly (77, 78, 82). Screw in until snug.
6. Install the reservoir (74). Slip the O-ring (80) over
the reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing.
7. Insert the plug (76) into the reservoir.
Assembly
Main Components
1. Remove the protective plastic bag from the
electronics subassembly.
2. Lay the gear housing/motor subassembly into the
right half of the housing. Insert the circuit board into
the circuit board recess.
3. Lay the wires into the case. Be sure that the wires
will not be pinched.
4. Guide the wires for the power cord so that the cord
lays on top of the electronics box.
5. Install the switch cover (51) and spring (56). Press
and release the trigger to be sure that it operates
freely.
6. Locate the right housing half on the top of the left
housing half. Check for pinched wires.
7. Install the housing screws (52).
8. Install the piston (8).
9. Replace the front head assembly. Twist the head
base (21) until it stops; back off 3/4 of a turn and
install the screw (35) and stop (36). Be sure that the
crimping head assembly rotates freely approximately
350°.
10. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the fill plug
(76) and fill the reservoir with hydraulic oil.
11. Plug the power cord into a live receptacle.
12. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir with hydraulic
oil. Replace the fill plug (76).
13.
Replace the tank cover and tank cover screws (52).

Greenlee / A Textron Company 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Illustration
5
4
6
7
8
2
52
50B
52
50C
3
1
50A
50D
51
56
55
10
9
54

Greenlee / A Textron Company 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Illustration
22
23
27
24
25
3
36
35
34
38
37
21
39
41
40
30
31
33
32
26

Greenlee / A Textron Company 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Illustration
72 73
83
79
81
70
80
71
76
74
82
75
77
78
155
156
150
153
152
151
154
128
129
122 123
124
120
121
130 125
126
127
96
92
91
101
93
102
103
100
108
109
106
105
107 104 99
112
97
95
111
94
110
90
12 11

Greenlee / A Textron Company 16 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Parts List
Key Part No. Description Qty
1500 1511.7 Decal, identification ........................................................................... 1
2 500 1425.0 Decal, safety, 120 volt ....................................................................... 1
500 1527.3 Decal, safety, 230 volt ....................................................................... 1
3500 6214.0 Decal, pinch hazard........................................................................... 2
4500 6773.7 Adapter.............................................................................................. 1
5500 6774.5 Screw ................................................................................................ 1
6* O-ring ................................................................................................ 1
7* Backup ring ....................................................................................... 1
8500 6779.6 Piston ................................................................................................ 1
9500 1560.5 Plate with microswitch, 120 volt ........................................................ 1
500 1689.0 Plate with microswitch, 230 volt ........................................................ 1
10 500 1561.3 Power cord, 120 volt.......................................................................... 1
500 1627.0 Power cord, 230 volt.......................................................................... 1
500 1559.1 Engine accessories kit (includes items 11–13)
11 500 1582.6 Capacitor ........................................................................................... 3
12 500 1581.8 Cable tie ............................................................................................ 1
13 500 1583.4 Tap, 4.8 x 0.5 (not shown)................................................................. 1
500 5373.6 C-head assembly, 42 mm (includes items 3, 21A, and 22–27)
500 7217.0 C-head assembly, 42 mm, PVC-covered
(includes items 3, 21B, and 22–27)
21A 500 5329.9 C-head............................................................................................... 1
21B 500 7222.6 C-head, PVC-covered ....................................................................... 1
22 905 5060.9 Set screw........................................................................................... 1
23 500 3821.4 Compression spring .......................................................................... 1
24 905 5063.3 Groove pin......................................................................................... 1
25 500 5317.5 Die release button ............................................................................. 1
26 500 5319.1 Die release pin .................................................................................. 1
27 905 5061.7 Set screw........................................................................................... 1
500 5378.7 Ram assembly (includes items 30–34)
30 500 3821.4 Compression spring .......................................................................... 1
31 500 5316.7 Die release pin .................................................................................. 1
32 500 5318.3 Release shaft .................................................................................... 1
33 905 5064.1 Spring pin .......................................................................................... 1
34 500 6670.6 Ram................................................................................................... 1
35 500 4367.6 Screw, M5 x 10.................................................................................. 1
36 500 6694.3 Stop ................................................................................................... 1
37 500 6692.7 Spring stop ........................................................................................ 1
38* O-ring ................................................................................................ 1
39 500 6691.9 Ram spring ........................................................................................ 1
40 500 6689.7 Screw ................................................................................................ 1
41 500 6690.0 Disc ................................................................................................... 1

Greenlee / A Textron Company 17 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Parts List (cont’d)
Key Part No. Description Qty
500 1563.0 Housing assembly, green (includes 50-58)
50A Housing, left side............................................................................... 1
50B Housing, right side............................................................................. 1
50C Reservoir cover ................................................................................. 1
50D Trigger guard..................................................................................... 1
51 500 1564.8 Switch cover ...................................................................................... 1
52 500 4207.6 Screw .............................................................................................. 14
54 500 1565.6 Cable clip........................................................................................... 1
55 500 1567.2 Protective cable cover ....................................................................... 1
56 500 1569.9 Compression spring .......................................................................... 1
57 500 1571.0 Film insulation (not shown)................................................................ 1
58 500 1566.4 Plug (not shown) ............................................................................... 1
500 1420.0 Pump housing, reservoir assembly (includes items 70–83)
70 501 0340.7 Ring tie .............................................................................................. 1
71 500 7177.7 Cable tie ............................................................................................ 1
72 500 4144.4 Threaded bushing ............................................................................. 1
73* O-ring ................................................................................................ 1
74 500 5873.8 Hydraulic reservoir ............................................................................ 1
75 500 4198.3 Ring ................................................................................................... 1
76 500 5878.9 Reservoir plug ................................................................................... 1
77 500 5880.0 Filter .................................................................................................. 1
78 500 5882.7 Filter adapter ..................................................................................... 1
79 500 5885.1 Threaded bushing ............................................................................. 1
80* O-ring ................................................................................................ 1
81 500 5829.0 Attachment ring ................................................................................. 1
82 500 5898.3 Magnet .............................................................................................. 1
83 500 1421.8 Pump housing ................................................................................... 1
500 1558.3 Motor assembly, 120 volt (includes items 90A and 91–112)
500 1605.9 Motor assembly, 230 volt (includes items 90B and 91–112)
90A 500 1577.0 Motor, 120 volt................................................................................... 1
90B 500 1606.7 Motor, 230 volt................................................................................... 1
91 500 4138.0 Ball bearing ....................................................................................... 1
92 500 4155.0 Screw ................................................................................................ 2
93 500 4157.6 Screw ................................................................................................ 4
94 500 1572.9 Gearbox............................................................................................. 1
95 500 1575.3 Insulating sleeve................................................................................ 1
96* Seal ................................................................................................... 1
97 500 1579.6 Hex nut .............................................................................................. 4
99 500 4163.0 Screw, socket head ........................................................................... 1
100 500 4151.7 Retaining ring .................................................................................... 1
101 500 4139.8 Grooved ball bearing ......................................................................... 1
102 500 4108.8 End cap ............................................................................................. 1
103 500 4123.1 Eccentric............................................................................................ 1
104 500 4922.4 Lock washer ...................................................................................... 1

Greenlee / A Textron Company 18 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240 and CK1240C CrimpingTools
Parts List (cont’d)
Key Part No. Description Qty
105 500 4125.8 Spring ................................................................................................ 1
106 500 5872.0 Screw ................................................................................................ 1
107 500 5879.7 Release lever .................................................................................... 1
108 500 8403.8 Screw ................................................................................................ 2
109 500 8402.2 Eccentric case ................................................................................... 1
110 500 1573.7 Motor flange ...................................................................................... 1
111 500 1574.5 Gear .................................................................................................. 1
112 500 1580.0 Screw ................................................................................................ 2
500 5903.3 Relief valve assembly (includes items 120–130)
120 500 5860.6 Washer .............................................................................................. 2
121* O-ring ................................................................................................ 1
122* Seal ................................................................................................... 1
123 500 5363.0 Valve seat.......................................................................................... 1
124 500 5864.9 Plunger .............................................................................................. 1
125* O-ring ................................................................................................ 1
126 500 5871.1 Adjusting nut...................................................................................... 1
127 500 5875.4 Support ring....................................................................................... 1
128* Retaining ring .................................................................................... 1
129 500 5877.0 Needle valve...................................................................................... 1
130 500 5894.0 Spring ................................................................................................ 1
500 1348.3 Piston pump assembly (includes items 150–156)
150 500 5891.6 Pump piston ...................................................................................... 1
151 501 0365.2 Screw plug......................................................................................... 1
152 501 0370.9 Pump piston ...................................................................................... 1
153* Washer .............................................................................................. 1
154* Sealing washer.................................................................................. 1
155 501 0367.9 Spring ................................................................................................ 1
156 501 0368.7 Valve stem......................................................................................... 1
*500 1409.9 Seal kit (includes items marked with an asterisk)
500 1523.0 Case with inserts
USA 800-435-0786 Fax: [phone]
815-397-7070 Fax: [phone]
Canada 800-435-0786 Fax: [phone]
International [phone] Fax: [phone]
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com Printed in USA