Greenlee GATOR EK1240K Bedienungsanleitung

GATOR®EK1240K and EK1240KC

Battery-powered Crimping Tool

with Two-speed Ram

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

KEEPTHIS MANUAL

Table of Contents

Description .....................................................................2

Purpose..........................................................................2

Important Safety Information ......................................3-4

Identification...................................................................5

Location of Decals .........................................................6

Specifications.................................................................6

Operation ....................................................................7-8

Maintenance ..................................................................9

Troubleshooting ...........................................................10

Disassembly/Reassembly.......................................11-12

Service .........................................................................13

Exploded Views ......................................................14-16

Parts List .................................................................17-19

Description

The EK1240K Hydraulic Crimping Tool is a hand-held,

self-contained, battery-powered tool intended to crimp

aluminum and copper connectors onto electrical cable.

The EK1240K accepts Kearney-style dies for crimping

various types of connectors onto #8 to 750 MCM wire.

The EK1240KC has a PVC-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

This instruction manual is intended to familiarize opera-

tors and maintenance personnel with the safe operation,

troubleshooting and repair procedures for the Greenlee

EK1240K and EK1240KC.

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.

GATOR is a registered trademark of Greenlee Textron.

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.

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

IMPORTANT SAFETY INFORMATION

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.

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

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 can

result in serious injury, gangrene or

death.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris or hydraulic oil.

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Failure to observe this warning can

result in severe injury or death.

Do not use solvents or flammable

cleaners to clean the tool body.

Solvents could ignite, causing

serious injury or property damage.

An incomplete crimp can cause a fire. Use proper

die, connector and cable combinations.

• Improper combinations can result in an incom-

plete 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 this warning can result in severe

injury or death.

• Keep hands away from the

crimping tool head when crimping.

• Lock trigger when not in use.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

IMPORTANT SAFETY INFORMATION

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.

• Do not operate tool without dies. Damage to the

ram or crimping head may result.

• Do not use this tool for continuous use. After

30 – 40 crimping cycles, allow the tool to cool for

15 minutes.

• Do not secure this tool in a vise. A vise can

damage the housing.

• Protect the tool from moisture. Any moisture

inside the housing can damage internal circuitry.

• Use this tool for the manufacturer’s intended use

only.

Failure to observe these precautions can result in

injury or property damage.

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 can result in

injury and property damage.

Do not dispose of batteries in a fire. They will vent

fumes and may explode.

Failure to observe this warning can result in

severe injury from harmful fumes or burns from

flying debris.

Do not allow anything to contact the battery

terminals.

• Do not immerse the batteries in liquid. Liquid

may create a short circuit and damage the

battery. If batteries are immersed, contact your

service center for proper handling.

• Do not place the battery into a pocket, tool

pouch or tool box with conductive objects.

Conductive objects may create a short circuit

and damage the battery.

• Do not place a battery on moist ground or

grass. Moisture may create a short circuit and

damage the battery.

Failure to observe these precautions can result in

injury or property damage.

• Do not store the battery at more than 60°C

(140°F). Damage to the battery can result.

• Do not use another manufacturer’s charger.

Other manufacturers’ chargers may overcharge

and damage the battery.

• Do not attempt to open the battery. It contains

no user-serviceable parts.

Failure to observe these precautions can result in

injury or property damage.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

Identification

EK1240K and EK1240KC

1. Housing 5. Trigger Lock Button

2. Retract Button 6. Trigger

3. Battery 7. Battery Load Display

4. Hand Guard 8. Die Release Set Screw

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

Location of Decals

Specifications

Crimping Tool

Length.....................................................................................396 mm (15.59")

Width ..........................................................................................80 mm (3.16")

Height .....................................................................................306 mm (12.03")

Mass/Weight (with Battery) ...................................................... 6.9 kg (15.2 lb)

Sound Level .....................................................................75 dB (A) at 1 meter

Vibration ........................................................................................... < 2.5 m/s2

Motor Voltage .......................................................................................12 VDC

Hydraulic Oil ............................................50 ml (0.1 pint) of Shell Tellus®T 15

Crimping Capacities

Crimping Range ...................................10 mm2to 400 mm2(#8 to 750 MCM)

Crimping Force.......................................................................106 kN (12 tons)

Battery

Charging Voltage..................................................................................12 VDC

Charging Time........................................................................................ 1 hour

500 6214.0

500 6509.2 (EK1240K)

500 7231.5 (EK1240KC)

(opposite side)

500 6506.8 (EK1240K)

500 7228.5 (EK1240KC)

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

Operation

Electric shock hazard:

This tool is not insulated. When

using this tool on or near energized

electrical lines, use proper personal

protective equipment.

Failure to observe this warning can

result in severe injury or death.

Wear eye protection when operating

this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris or hydraulic oil.

An incomplete crimp can cause a fire. Use proper

die, connector and cable combinations.

• Improper combinations can result in an incom-

plete 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 can 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 can

result in serious injury, gangrene or

death.

• Keep hands away from the

crimping tool head when crimping.

• Lock trigger when not in use.

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

SIDE B

The battery indicator illuminates to show battery charge

level as follows:

Normal: Illuminates momentarily at beginning of crimp.

Normal: Flickering at point of maximum crimping force.

Low charge: Flickering during entire crimping cycle.

Low charge: Illuminates continuously when operating

without a load.

1. Clean the die seat area.

2. Install the proper size and type of crimping dies.

3. Insert one of the die halves into the ram by pressing

the die stem into the hole located in the ram.

4. Insert the other die half into the C-head by pressing

the die stem into the hole located in the C-head.

The die half can then be locked in place by tighten-

ing the lock screw.

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.

7. Press the trigger lock button to release the trigger.

8. 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.”

9. After achieving pressure relief, the ram will auto-

matically return to the start position and the dies will

retract.

10. Complete the number of crimps specified by the

connector manufacturer.

11. Remove connector from crimper.

Note: After completing the last crimp on an

aluminum connector, wipe off the excess

oxide inhibitor.

Operation (cont’d)

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

Maintenance

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 can

result in serious injury, gangrene or

death.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris or hydraulic oil.

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 housing to dry.

2. Fully retract the ram and lock the trigger. Place the

crimping tool in the carrying case and store in a

cool, dry place.

3. If necessary, recharge the batteries – see the

instructions supplied with the battery charger.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

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 15

NUTO®H 15

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.

Relief valve adjustments must be done by an

authorized service center.

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK1240K and EK1240KC

Troubleshooting

PROBLEM PROBABLE CAUSE POSSIBLE REMEDY

Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.

of tool.

Crimping tool battery contacts damaged. Reform contacts.

Tool components worn or damaged. Return tool to an authorized

Greenlee service center.

Dead battery. Charge or replace.

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.

Battery load display flashes Battery charge low. Charge or replace battery.

constantly.

Tool loses oil. Damaged internal seal. Return tool to an authorized Greenlee

service center.

Oil plug not installed properly. Refill reservoir and replace plug.

BEFORE YOU BEGIN

1. Make sure that the battery is charged. Recheck the

battery after several minutes to make sure the

battery is holding its charge.

2. Use a NONFLAMMABLE contact cleaner or pencil

eraser to clean the electrical contacts on the battery

and crimping tool.

3. Reinstall battery and check the tool again.

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