Greenlee GATOR CK1240K User manual

INSTRUCTION MANUAL
99945002 © 2008 Greenlee Textron Inc. IM 1509 REV 2 4/08
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR®
CK1240K and CK1240KC
Crimping Tools
120 Volt and 230 Volt
Serialnummer

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240K and CK1240KC Crimping Tools
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.
Tellus is a registered trademark of Shell Oil Company.
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
General Safety Rules ................................................. 3–5
Identification ................................................................... 6
Specifications ................................................................. 6
Operation ....................................................................... 7
Maintenance................................................................... 8
Periodic Pressure Relief Valve Check ........................... 8
Troubleshooting ............................................................. 9
Service Center Information
Disassembly ................................................................. 10
Assembly...................................................................... 11
Illustrations ............................................................. 12–14
Parts List ................................................................ 15–17
Description
The CK1240K Hydraulic Crimping Tool is a hand-held,
self-contained tool intended to crimp aluminum and
copper connectors onto electrical cable.
The CK1240KC 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:
CK1240K11 120 V Crimping Tool
CK1240KC11 120 Volt Crimping Tool
with PVC-covered Head
CK1240K22 230 Volt Crimping Tool
CK1240KC22 230 Volt Crimping Tool
with PVC-covered Head
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge at www.greenlee.com

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240K and CK1240KC Crimping Tools
SAVE THESE
INSTRUCTIONS
GENERAL SAFETY RULES
Read all instructions. Failure to
follow instructions listed below may
result in electric shock, fire, and/or
serious injury. The term “power tool”
in all of the warnings listed below
refers to your mains-operated
(corded) power tool.
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
Electrical safety:
•Power tool plugs must match
the outlet. Never modify the
plug in any way. Do not use any
adapter plugs with earthed
(grounded) power tools. Unmodi-
fied plugs and matching outlets will
reduce risk of electric shock.
•Avoid body contact with earthed
or grounded surfaces such as
pipes, radiators, ranges, and
refrigerators. There is an
increased risk of electric shock if
your body is earthed or grounded.
•Do not expose power tools to
rain or wet conditions. Water
entering a power tool will increase
the risk of electric shock.
•Do not abuse the cord. Never
use the cord for carrying,
pulling, or unplugging the
power tool. Keep cord away
from heat, oil, sharp edges, or
moving parts. Damaged or
entangled cords increase the risk
of electric shock.
•When operating a power tool
outdoors, use an extension cord
suitable for outdoor use marked
“W-A” or “W”. Use of a cord
suitable for outdoor use reduces
the risk of electric shock.
Failure to observe these warnings
could result in severe injury or death.
Work area safety:
•Keep work area clean and well lit. Cluttered or
dark areas invite accidents.
•Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases, or dust. Power tools
create sparks which may ignite the dust or fumes.
•Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
Failure to observe these warnings could result in
severe injury or death.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
CK1240K and CK1240KC Crimping Tools
Personal safety:
•Stay alert, watch what you are doing, and use
common sense when operating a power tool.
Do not use a power tool while you are tired or
under the influence of drugs, alcohol, or
medication. A moment of inattention while
operating power tools may result in serious
personal injury.
•Use safety equipment. Always wear eye
protection. Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will
reduce personal injuries.
•Avoid accidental starting. Ensure the switch
is in the off-position before plugging in.
Carrying power tools with your finger on the
switch or plugging in power tools that have the
switch on invites accidents.
•Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
•Dress properly. Do not wear loose clothing or
jewelry. Keep your hair, clothing, and gloves
away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving
parts.
Failure to observe these warnings could result in
severe injury or death.
GENERAL SAFETY RULES
Power tool use and care:
•Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
•Do not use the power tool if the switch does
not turn it on and off. Any power tool that
cannot be controlled with the switch is dangerous
and must be repaired.
•Disconnect the plug from the power source
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
•Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instructions to
operate the power tool. Power tools are
dangerous in the hands of untrained users.
•Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts,
and any other condition that may affect the
power tool’s operation. If damaged, have the
power tool repaired before use. Many
accidents are caused by poorly maintained
power tools.
•Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
•Use the power tool, accessories, and tool bits,
etc., in accordance with these instructions
and in the manner intended for the particular
type of power tool, taking into account the
working conditions and the work to be
performed. Use of the power tool for operations
different from those intended could result in a
hazardous situation.
Failure to observe these warnings could result in
severe injury or death.
Service:
Have your power tool serviced by a qualified
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
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
CK1240K and CK1240KC Crimping Tools
GENERAL SAFETY RULES
Note: Keep all decals clean and legible, and replace
when necessary.
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.
Electric shock hazard:
•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.
Electric shock hazard:
•Inspect the power cord before use.
Repair or replace the cord if
damaged.
•Disconnect from power before
servicing.
Failure to observe these warnings
could result in severe injury or death.
Pinch hazard:
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 without dies. Damage to
the ram or crimping tool head may result.
•This tool is not designed for continuous use.
After 20 crimping cycles, allow the crimping tool
to cool for 20 minutes.
•Do not place the tool in a vise. The crimping tool
is designed for hand-held operation.
Failure to observe these precautions may result in
injury or property damage.
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 64455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
Identification
Specifications
CK1240K and CK1240KC
1. Housing
2. Retract Button
3. Power Cord
4. Trigger
5. Die Release Set Screw
Crimping Tool
Class II tool, double insulated
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
CK1240K11 and CK1240KC11 ........................................ 120 VAC, 60 Hz, 2.1 A
CK1240K22 and CK1240KC22 ........................................ 230 VAC, 50 Hz, 1.1 A
Symbols on Tool
V .................................................................................................................... volts
~.............................................................................................. alternating current
A ............................................................................................................. amperes
Hz ................................................................................................................. hertz
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
CK1240K and CK1240KC Crimping Tools
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. 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.
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.
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.
Electrical safety:
Avoid body contact with earthed
or grounded surfaces such as
pipes, radiators, ranges, and
refrigerators. There is an increased
risk of electric shock if your body is
earthed or grounded.
Failure to observe this warning could
result in severe injury or death.
Personal safety:
Use safety equipment. Always wear eye
protection. Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will
reduce personal injuries.
Failure to observe this warning could result in
severe injury or death.
Pinch hazard:
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 84455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
Maintenance
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 Oil
Shell Tellus T 15
Periodic Pressure Relief Valve 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.
Personal safety:
Use safety equipment. Always wear eye
protection. Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will
reduce personal injuries.
Failure to observe this warning could result in
severe injury or death.
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 hazard:
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 94455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
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 10 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
Disassembly
Main Components
1. Loosen the screw (24). Remove the screw (31) and
stop (30).
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).
SERVICE CENTER INFORMATION
Service:
Have your power tool serviced by a qualified
repair person using only identical replacement
parts. This will ensure that the safety of the power
tool is maintained.
Failure to observe this warning could result in
severe injury or death.

Greenlee / A Textron Company 11 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
SERVICE CENTER INFORMATION
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. Loosely assemble the insulation paper (118) around
the motor case. Align the front edge to assure the
motor cooling holes are not covered.
3. Lay the gear housing/motor subassembly into the
right half of the housing. Insert the circuit board into
the circuit board recess.
4. Lay the wires into the case. Be sure that the wires
will not be pinched.
5. Guide the wires for the power cord so that the cord
lays on top of the electronics box.
6. Install the switch cover (51) and spring (56). Press
and release the trigger to be sure that it operates
freely.
7. Locate the right housing half on the top of the left
housing half. Check for pinched wires.
8. Install the housing screws (52).
9. Install the piston (8).
10. Replace the front head assembly. Twist the head
base (21) until it stops; back off 3/4 of a turn and
install the screw (31) and stop (30). Be sure that the
crimping head assembly rotates freely approximately
350°.
11. 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.
12. Plug the power cord into a live receptacle.
13. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir completely
with hydraulic oil. Replace the fill plug (76).
14.
Replace the tank cover and tank cover screws (52).

Greenlee / A Textron Company 12 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
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 13 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
SERVICE CENTER INFORMATION
Illustration
34
32
22
24
21
32
31
3
23
30
33
35
36
38
37

Greenlee / A Textron Company 14 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
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
118

Greenlee / A Textron Company 15 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
SERVICE CENTER INFORMATION
Parts List
Key Part No. Description Qty
1 50015192 Decal, identification ........................................................................... 1
2 50014250 Decal, safety, 120 volt ....................................................................... 1
50015273 Decal, safety, 230 volt ....................................................................... 1
3 50062140 Decal, pinch hazard........................................................................... 2
4 50067737 Adapter .............................................................................................. 1
5 50067745 Screw ................................................................................................ 1
6* O-ring ................................................................................................ 1
7* Backup ring ....................................................................................... 1
8 50067796 Piston ................................................................................................ 1
9 50015605 Plate with microswitch, 120 volt ........................................................ 1
50016890 Plate with microswitch, 230 volt ........................................................ 1
10 50015613 Power cord, 120 volt.......................................................................... 1
50016270 Power cord, 230 volt.......................................................................... 1
50015591 Engine accessories kit (includes items 11–13)
11 50015826 Capacitor ........................................................................................... 3
12 50015818 Cable tie ............................................................................................ 1
13 50015834 Tap, 4.8 x 0.5 (not shown)................................................................. 1
50054767 C-head assembly, 42 mm (includes items 3, 21A, and 22–24)
50072188 C-head assembly, 42 mm, PVC-covered
(includes items 3, 21B, and 22–24)
21A 50053352 C-head............................................................................................... 1
21B 50072234 C-head, PVC-covered ....................................................................... 1
22 90507932 Set screw........................................................................................... 1
23 90539621 Ball detent ......................................................................................... 1
24 90550617 Set screw........................................................................................... 1
30 50066943 Stop ................................................................................................... 1
31 50043676 Screw, M5 x 10.................................................................................. 1
32 90539621 Ball detent ......................................................................................... 3
33 50066714 Ram ................................................................................................... 1
34 50067265 Spring stop ........................................................................................ 1
35* O-ring ................................................................................................ 1
36 50066919 Ram spring ........................................................................................ 1
37 50066951 Screw ................................................................................................ 1
38 50066900 Disc ................................................................................................... 1
50015630 Housing assembly, green (includes 50-58)

Greenlee / A Textron Company 16 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
Parts List (cont’d)
Key Part No. Description Qty
50A Housing, left side ............................................................................... 1
50B Housing, right side............................................................................. 1
50C Reservoir cover ................................................................................. 1
50D Trigger guard ..................................................................................... 1
51 50015648 Switch cover ...................................................................................... 1
52 50042076 Screw .............................................................................................. 14
54 50015656 Cable clip........................................................................................... 1
55 50015672 Protective cable cover ....................................................................... 1
56 50015699 Compression spring .......................................................................... 1
57 50015710 Film insulation (not shown)................................................................ 1
58 50015664 Plug (not shown) ............................................................................... 1
50014200 Pump housing, reservoir assembly (includes items 70–83)
70 50103407 Ring tie .............................................................................................. 1
71 50071777 Cable tie ............................................................................................ 1
72 50041444 Threaded bushing ............................................................................. 1
73* O-ring ................................................................................................ 1
74 50058738 Hydraulic reservoir ............................................................................ 1
75 50041983 Ring ................................................................................................... 1
76 50058789 Reservoir plug ................................................................................... 1
77 50058800 Filter .................................................................................................. 1
78 50058827 Filter adapter ..................................................................................... 1
79 50058851 Threaded bushing ............................................................................. 1
80* O-ring ................................................................................................ 1
81 50058290 Attachment ring ................................................................................. 1
82 50058983 Magnet .............................................................................................. 1
83 50014218 Pump housing ................................................................................... 1
50015583 Motor assembly, 120 volt (includes items 90A and 91–112)
50016059 Motor assembly, 230 volt (includes items 90B and 91–112)
90A 50015770 Motor, 120 volt................................................................................... 1
90B 50016067 Motor, 230 volt................................................................................... 1
91 50041380 Ball bearing ....................................................................................... 1
92 50041550 Screw ................................................................................................ 2
93 50041576 Screw ................................................................................................ 4
94 50015729 Gearbox............................................................................................. 1
95 50015753 Insulating sleeve................................................................................ 1
96* Seal ................................................................................................... 1
97 50015796 Hex nut .............................................................................................. 4
99 50041630 Screw, socket head ........................................................................... 1
100 50041517 Retaining ring .................................................................................... 1
101 50041398 Grooved ball bearing ......................................................................... 1
102 50041088 End cap ............................................................................................. 1
103 50041231 Eccentric............................................................................................ 1
104 50049224 Lock washer ...................................................................................... 1

Greenlee / A Textron Company 17 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815-397-7070
CK1240K and CK1240KC Crimping Tools
SERVICE CENTER INFORMATION
SERVICE CENTER INFORMATION
Parts List (cont’d)
Key Part No. Description Qty
105 50041258 Spring ................................................................................................ 1
106 50058720 Screw ................................................................................................ 1
107 50058797 Release lever .................................................................................... 1
108 50084038 Screw ................................................................................................ 2
109 50084022 Eccentric case ................................................................................... 1
110 50015737 Motor flange ...................................................................................... 1
111 50015745 Gear .................................................................................................. 1
112 50015800 Screw ................................................................................................ 2
118 Insulation ........................................................................................... 1
50059033 Relief valve assembly (includes items 120–130)
120 50058606 Washer .............................................................................................. 2
121* O-ring ................................................................................................ 1
122* Seal ................................................................................................... 1
123 50053630 Valve seat.......................................................................................... 1
124 50058649 Plunger .............................................................................................. 1
125* O-ring ................................................................................................ 1
126 50058711 Adjusting nut...................................................................................... 1
127 50058754 Support ring ....................................................................................... 1
128* Retaining ring .................................................................................... 1
129 50058770 Needle valve...................................................................................... 1
130 50058940 Spring ................................................................................................ 1
50013483 Piston pump assembly (includes items 150–156)
150 50058916 Pump piston ...................................................................................... 1
151 50103652 Screw plug......................................................................................... 1
152 50103709 Pump piston ...................................................................................... 1
153* Washer .............................................................................................. 1
154* Sealing washer .................................................................................. 1
155 50103679 Spring ................................................................................................ 1
156 50103687 Valve stem......................................................................................... 1
* 50014099 Seal kit (includes items marked with an asterisk)
50015230 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