Greenlee HK06ATC User's Manual
Contents
1. 5 2 Socket head cap screw 2 Fixed tine tit aM 1 Moving side JAW 2 Pivotroller J tte Acton eet tm eee ers 2 o oos 2 Socket head cap screw 2 Socket head cap screw 1 ies RUE 1 KI 1 Oting eves eek te cie be ee tt 1 Backup ring piston init e E ERR iia rs 1 Spring compression o 1 Dowell pin 4x 20 mm cierta 1 Decal pinch hazard ci ee e 1 Decal ID and warning 1 Steel Case oae Eee dg ain Cerea eap un 1 Seal kit includes items marked with an asterisk Bearing retainer kit includes items 103 and 104 Test gage 10 test slugs 10 slugs with 10 000 psi gage GREENLEE DARCI Greenlee Textron Subsidiary of Textron Inc 4455 Boeing Drive Rockford IL 61109 2988 USA Customer Service International 815 397 7070 Fax 815 397 9247 Customer Service North America 800 435 0786 USA Fax 800 451 2632 815 397 1865 Canada Fax 800 524 2853 www greenlee textron com Printed in the USA2. INSTRUCTION MANUAL GREENLEE HKOGAT and HKOGATC Hydraulic Crimping Tools Read and understand all of the instructions and safety information in this manual before operating or servicing this tool 999 3089 7 2001 Greenlee Textron 1368 REV 1 10 01 GREENLEE and HKOGATC Table of Contents Descriptor oou ER e 2 PR DM EH MM 2 Purpose this Manual 2 Important Safety Information 3 4 ldentification 5 Specifications 5 Operation ees 6 Periodic Pressure Relief Valve Check 7 Il Strations a ORAE 8 10 Patts LIst 2 sinit 11 12 Description The and HKO6ATC Hydraulic Crimping Tools are hand held self contained dieless crimping tools intended to crimp aluminum and copper connectors onto electrical cable The has a rubber covered crimping head Safety Safety is essential in the use and maintenance of Greenlee tools and equipment This instruction 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 instruction manual is intended to familiarize al
3. Greenlee service center GO NO GO Greenlee Textron Subsidiary of Textron Inc 7 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Illustration Greenlee Textron Subsidiary of Textron Inc 8 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Illustration Greenlee Textron Subsidiary of Textron Inc 9 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Illustration Greenlee Textron Subsidiary of Textron Inc 10 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Parts List Key OOA 0 IO IO IO IO IO IO IO IO ZA a n o o HTD AN DOA Oo gt CO O qo 41 42 43 44 45 46 47 Greenlee Subsidiary of Textron Inc Part No 500 6384 7 500 6345 6 500 6346 4 500 6348 0 500 6349 9 500 6354 5 500 6355 3 500 5882 7 500 6344 8 500 6356 1 501 0376 8 500 6358 8 500 6360 0 500 6361 8 500 6364 2 500 6782 6 500 5878 9 500 6342 1 500 6343 0 500 6368 5 500 6369 3 500 4143 6 500 5886 0 500 6370 7 500 6371 5 500 4144 4 500 4145 2 500 5885 1 500 6372 3 500 6373 1 501 0377 6 500 5880 0 500 5898 3 500 6375 8 500 6377 4 500 5876 2 500 6335 9 500 63
4. SIDE B 1ST COMPRESSION SIDE A N 1ST COMPRESSION SIDE B CRIMPING DIRECTION SIDE A Using the sequence illustrated here pump the handles to advance the nibs Continue to pump until the pressure relief valve activates Note Pressure relief occurs at approximately 55 kN 6 2 tons and is indicated by an audible pop After achieving pressure relief the ram automati cally returns to the start position and the nibs retract Complete the number of crimps specified by the connector manufacturer 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Periodic Pressure Relief Valve Check Test the crimping tool periodically to ensure that the pressure relief valve activates at the proper pressure Testing the Crimping Tool 1 Center a test slug between the nibs 2 Pump the handle to advance the nibs Continue pumping until the pressure relief valve activates 3 After achieving pressure relief the ram automati cally returns to the start position and the nibs retract 4 Evaluate the test slug as follows If the test slug does not fit into GO slot the pressure relief valve is set too high Send the crimping tool to an authorized Greenlee service center If the test slug fits into the GO slot the pressure relief valve is set correctly If the test slug fits into the NO GO slot the pressure relief valve is set too low Send the crimping tool to an authorized
5. 31 6 500 6378 2 500 5863 0 500 5864 9 500 6379 0 500 6380 4 500 5894 0 500 5869 0 Description Qty Pump body onu dendo ei 1 PUIMP PISTOM E 1 Sl66V6 iii eite HR BE edat pin sesh vse bes 1 atl M EE 1 SGrewiplu ig s oci me aie d ee ear tet imo tae 1 Release pli eed ax eee etai tuse 1 Release lever a eee tein 1 Filter adapter 1 Resetvolr e tm eai er tto ep die dees 1 P rnp hiangdle uu weet dip get ip esa 1 Handl lock Ee 1 a adu tetto fep ca echt area 2 Release knob urbe BR DIES 1 ac 1 Handle piri niit Gaede 4 Handle tube Ait ee 1 plug sigro ssn att tera ente td e i 1 Grip 251 1 Grip 32 eet peg te qe p 1 Orig stu ud eon cipio um 1 sie teu aie e a 1 colas ie eet m etin Aparte secuti Lees 1 OTING EUER ER ett nec oc p e 1 OTING s coi act fede etm m tds ns 1 ttm eau en eg 1 Threaded bu shing ont terere etes 1 Threaded bushing ET 1 Threaded bushing eese ener nnne 1 Spring 5 1 Spring compression n nece nei iin 1 Spring comhpression cente ede eco kate irent 1 i Ei D DEBOUT i 1 Magrilel rnt m c eae ete om 1 ei ronde e Te
6. ed bl e ee dt tria cis 1 Roll pin gestae ate a E 1 Retaining TING ois et cote no ed eee 9 FROTAIN ING FING 1 Pressure adjustment cartridge includes items 41 49 1 Cartridge body een cd neci pt eie o deas 1 Valve seats oefe ee d detecta eec eric ees 1 Pl rigers ER 1 Needle Valve EE 1 Pressure adjustment screw 1 ep ERU PIRE UH 1 OMNO td EE 1 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Parts List cont d Key 48 49 50 101A 101B 102 103 104 105 106 110 112 113 114 115 116 201 202 203 204 205 206 Kits Part No 500 5862 2 500 5860 6 500 7177 7 500 6095 3 500 6526 2 500 6092 9 500 6089 9 500 6088 0 500 6091 0 500 6100 3 500 6084 8 500 6085 6 500 6086 4 500 6087 2 500 6101 1 500 6099 6 500 6381 2 500 6382 0 500 4192 4 500 4194 0 500 5839 8 500 6340 5 500 6214 0 500 6079 1 500 6391 0 500 6395 2 500 6129 1 500 6309 0 500 6308 1 500 6130 5 Description Qty MM M 2 Washer minii dudo 2 RING tle oie dot BREUI cs 1 Head cover set with decal 1 Rubber coated head cover set with decal 1 Cam yoke assembly 1 Roller bearings n RO gehe eee 12 Bearing retainers soe e uite orto ed 2 Spring
7. er personal protective equipment Failure to observe this warning can result in severe injury or death AWARNING Wear eye protection when operating this tool Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil AWARNING Skin injection hazard Oil under pressure easily punctures skin causing serious injury gan grene or death If you are injured by escaping oil seek medical attention immediately Do not use hands to check for leaks Depressurize the hydraulic system before servicing AWARNING An incomplete crimp can cause a fire Use proper connector and cable combinations Improper combinations can result in an incom plete crimp The handle load will drop suddenly to indicate a completed crimp If the handle load does not drop suddenly the crimp is not complete Failure to observe these warnings can result in severe injury or death Greenlee Textron Subsidiary of Textron Inc Follow the lug manufacturer s instructions for appropriate cable strip length and surface prep aration Insert cable fully into connector Center the con nector between the nibs ACAUTION Small connectors may become wedged between the nibs of the tool Center the connector between the four nibs before crimping Failure to observe this precaution can cause property damage CRIMPING DIRECTION 277 N 1ST COMPRESSION CRIMPING DIRECTION
8. erve these warnings can result in Failure to observe these precautions can result in severe injury or death injury and property damage A WARN NG Note Keep decals clean and legible Replace decals when necessary Inspect tool before use Replace any worn or dam aged parts A damaged or improperly assembled tool can break and strike nearby personnel Failure to observe this warning can result in severe injury or death Greenlee Textron Subsidiary of Textron Inc 4 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Identification 3 4 HKOGAT 1 Crimping Head 3 Release Lever 2 Handle Lock 4 Pump Body Specifications Crimping Tool ETE 552 21 75 Width rec a ee ve i 191 7 5 mE pp 63 5 mm 2 5 Mass Weight 4 5 kg 9 9 Ib Hydraulic 150 ml 0 3 pint of Shell Tellus T 15 Crimping Capacities Crimping Range cm 8 AWG to 500 Kcmil Aluminum ene cune de 8 AWG to 400 Kcmil Crimping FORCE eevee tice ees 55 6 2 tons Greenlee Subsidiary Textron Inc 5 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC Operation AWARNING Electric shock hazard This tool is not insulated When using this tool on or near energized electrical lines use prop
9. idiary of Textron Inc AWARNING 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 can result in severe injury or death AWARNING Wear eye protection when operating this tool Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil AWARNING Skin injection hazard Oil under pressure easily punctures skin causing serious injury gan grene or death If you are injured by escaping oil seek medical attention immediately Do not use hands to check for leaks Depressurize the hydraulic system before servicing 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC IMPORTANT SAFETY INFORMATION AWARNING ACAUTION An incomplete crimp can cause a fire e This tool is intended for two handed operation Use proper connector and cable combinations Maintain a firm grip on both handles during Improper combinations can result in an incom operation Using this tool in any other manner can plete crimp result in injury or property damage The handle load will drop suddenly to indicate Do not operate the tool without a connector in completed crimp If the handle load does not place Damage to the ram or crimping tool head drop suddenly the crimp is not complete can result Failure to obs
10. l personnel with the safe operation of the Greenlee HKO6AT HKO6ATC Keep this manual available to all personnel Replacement manuals are available upon request at no charge All specifications are nominal and may change as design improve ments occur Greenlee Textron shall not be liable for damages resulting from misapplication or misuse of its products Tellus is a registered trademark of Shell Oil Company KEEP THIS MANUAL Greenlee Textron Subsidiary of Textron Inc 2 4455 Boeing Dr Rockford IL 61109 2988 815 397 7070 GREENLEE and HKOGATC IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL 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 ADANGER Immediate hazards which if not avoided WILL result in severe injury or death AWARNING Hazards which if not avoided COULD result in severe injury or death ACAUTION Hazards or unsafe practices which if not avoided MAY result in injury or property damage AWARNING Read and understand all of the instructions and safety information lt in this manual before operating or servicing this tool Failure to observe this warning can result in severe injury or death Greenlee Textron Subs
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