Greenlee GATOR EK210 Bedienungsanleitung

INSTRUCTION MANUAL

GATOR®EK210

Battery-powered

Crimping Tool

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Serialnummer

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Description

The EK210 Battery-powered Crimping Tool is a

hand-held, self-contained crimping tool intended to

crimp cable using Kwik Cycle®9 die sets.

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 tool:

EK210 Battery-powered Crimping Tool

Keep this manual available to all personnel.

Replacement manuals are available upon request at

no charge at www.greenlee.com.

All specications are nominal and may change as design

improvements occur. Greenlee Textron Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

GATOR and Kwik Cycle are registered trademarks of

Greenlee Textron Inc.

Tellus is a registered trademark of Shell Oil Company.

KEEP THIS MANUAL

Table of Contents

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

Safety ............................................................................. 2

Purpose of this Manual .................................................. 2

Important Safety Information ..................................... 3–4

Identication................................................................... 5

Specications................................................................. 5

Operation.................................................................... 6–7

Maintenance................................................................... 8

Troubleshooting.............................................................. 8

Illustrations ............................................................... 9–10

Parts List ...................................................................... 11

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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, dened below,

indicates the severity of the hazard. The message

after the signal word provides information for pre-

venting or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

Hazards which, if not avoided, COULD result in

severe injury or death.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Failure to observe this warning could

result in severe injury or death.

Electric shock hazard:

This tool is not insulated. When

using this unit 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 ying

debris or hydraulic oil.

Skin injection hazard:

Do not use hands to check for

oil leaks. High pressure oil easily

punctures skin causing serious

injury, gangrene, or death. If injured,

seek medical help immediately to

remove oil.

Do not use solvents or ammable

liquids to clean the crimping tool.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

An incomplete crimp can cause a re.

Use proper die, connector, and cable combina-

tions. Improper combinations can result in an

incomplete crimp.

The relief valve will sound to indicate a completed

crimp. If you do not hear the sound of the relief

valve, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

•

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Pinch points:

Keep hands away from the crimping

head when crimping.

Failure to observe this warning could

result in severe injury or death.

Do not dispose of batteries in a re. They will vent

fumes and may explode.

Failure to observe this warning could result in severe

injury from harmful fumes or burns from ying debris.

Inspect tool and dies before use. Replace any

worn or damaged parts. A damaged or improp-

erly 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 head can result.

Do not operate with the crimping head open.

Damage to the ram or seals can result.

This tool is not designed for continuous use. After

100 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.

This tool may be used in damp or wet environ-

ments; however, we recommend air-drying the tool

before use if it becomes soaked.

Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

•

IMPORTANT SAFETY INFORMATION

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 may 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 may 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 may result in injury

and property damage.

Note: Keep all decals clean and legible, and replace

when necessary.

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Identiﬁcation

Speciﬁcations

Crimping Tool

Length ..................................................................................................356 mm (14")

Width................................................................................................. 60 mm (2-3/8")

Depth................................................................................................. 80 mm (3-1/8")

Mass/Weight (with battery)...................................................................1.3 kg (2.8 lb)

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

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

Hydraulic Oil...................................................................................Shell Tellus®T 15

Crimping Capacities

Maximum Crimping Force................................................................ 13 kN (1.5 tons)

Average Crimping Time.............................................................................2 seconds

Average Crimps per Charge.........................................................approximately 150

Battery

Charging Voltage............................................................................................... 9.6 V

Charging Time.................................................................................................45 min

1. Crimping Dies

2. Crimping Head

3. Retract Button

4. Battery Lock

5. Battery Cartridge

6. Trigger

7. LED Display

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Operation

Electric shock hazard:

This tool is not insulated. When

using this unit 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 ying

debris or hydraulic oil.

Pinch points:

Keep hands away from the crimping

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 head can result.

Do not operate with the crimping head open.

Damage to the ram or seals can result.

This tool is not designed for continuous use. After

100 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.

This tool may be used in damp or wet environ-

ments; however, we recommend air-drying the tool

before use if it becomes soaked.

Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

•

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Operation (cont’d)

Charging the Battery

Read the instructions supplied with the battery charger.

LED Display

This tool is equipped with a special circuit board incor-

porating several important features to inform the user

about the currect status of the unit. The LED signals in

the following cases:

Installing Dies

1. Select the proper dies for the intended crimp.

2. Slide the die into the crimping head and secure with

screw.

3. Properly position the second die. Repeat Step 2.

Preparing Cable

Follow the lug manufacturer’s instructions for appropri-

ate cable strip length.

Signal Duration When it occurs What it means

a few seconds of battery insertion self check - O.K.

ﬂashing

glowing for after crimp battery discharged

20 seconds

ﬂashing for after crimp time for inspection

20 seconds (2Hz) and preventive

maintenance

20 sec. glowing after crimp

battery discharged—

and ﬂashing time for inspection

intermittently and preventive

maintenance

Crimping Cable

1. Insert the properly assembled connector into the

crimping head.

2. Pull the trigger to make the crimp.

3. Hold the trigger down until the crimping tool

achieves pressure relief, which is accompanied by

an audible “pop”.

4. The crimping tool returns automatically.

5. Position the crimping tool for next crimp. Repeat

Steps 2 and 3 for the number of crimps as

described in this manual.

Note: If it is necessary to retract the ram before a

crimping cycle is completed, push the retract button.

Pushing the retract button will result in the complete

retraction of the ram.

An incomplete crimp can cause a re.

Use proper die, connector, and cable combina-

tions. Improper combinations can result in an

incomplete crimp.

The relief valve will sound to indicate a completed

crimp. If you do not hear the sound of the relief

valve, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

•

Crimping Direction

First Compression

Crimping Direction

SIDE A

Crimping Direction

SIDE B

First Compression

SIDE A

First Compression

SIDE B

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Maintenance

Each Operating Day

Before use:

1. Inspect dies for wear or damage such as cracks,

gouges, or chips.

2. Inspect the tool for damage or leaks. If damage is

detected, return the tool to an authorized Greenlee

service center for inspection.

Skin injection hazard:

Do not use hands to check for oil

leaks. High pressure oil easily

punctures skin causing serious

injury, gangrene, or death. If injured,

seek medical help immediately to

remove oil.

After use:

1. Wipe all tool surfaces clean with a damp cloth and

mild detergent.

Do not use solvents or ammable

liquids to clean the crimping tool.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

2. Fully retract the ram. Place the tool in the carrying

case. Store in a cool, dry place.

3. Charge the battery.

Monthly

Thoroughly clean all surfaces.

Annually or After 10,000 Crimps

Return the tool to an authorized Greenlee service center

for inspection.

Troubleshooting

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 the battery and check the tool again.

Problem Probable Cause Probable Remedy

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

of tool.

Clean tool.

Crimping tool battery contacts

damaged.

Reform contacts.

Tool components worn or damaged. Return tool to an authorized

Greenlee service center.

Dies stop during operation. Oil level is low. Return tool to an authorized

Greenlee service center.

Air in hydraulic system. Pull trigger and hold retract button

simultaneously. Hold for approxi-

mately 10 seconds.

LED glows for 20 seconds. Battery charge low. Charge or replace battery.

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

Greenlee service center.

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Illustrations—Main

141

10 11

146

144

143

147

142

148

145

140

141

96 94

EK210 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Illustrations (cont’d)

55 50

35 36 37

123

122

121

120

Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly

Motor Assembly

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