Greenlee GATOR EK22GL Bedienungsanleitung

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

GATOR®Plus

EK22GL

Battery-powered,

High-speed Crimping Tool

Serialnummer

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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.

Blackburn is a registered trademark of Thomas & Betts.

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.

KEEP THIS MANUAL

Table of Contents

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

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

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

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

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

Specifications ................................................................. 5

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

Die Selection .................................................................. 8

Connector Selection ....................................................... 8

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

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

Disassembly ................................................................. 11

Assembly...................................................................... 12

Illustrations ............................................................. 13–15

Parts List ................................................................ 16–18

Description

The EK22GL Battery-powered, High-speed Crimping

Tool is a hand-held, self-contained crimping tool

intended to crimp copper and aluminum cable with

KC22-type, KA22-type, and W-type dies.

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:

EK22GL Battery-powered, High-speed

Crimping Tool

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge.

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

IMPORTANT SAFETY INFORMATION

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

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.

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.

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.

Do not use solvents or flammable

liquids to clean the crimping tool.

Solvents or flammable liquids could

ignite and cause serious injury or

property damage.

An incomplete crimp can cause a fire.

•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.

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.

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

IMPORTANT SAFETY INFORMATION

Note: Keep all decals clean and legible, and replace

when necessary.

Inspect tool and dies before use. Replace any worn or

damaged 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 dispose of batteries in a fire. They will vent

fumes and may explode.

Failure to observe this warning could 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 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.

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 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.

• Protect the crimping tool from rain and moisture.

Water will damage the crimping tool and battery.

•Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

EK22GL Battery-powered, High-speed Crimping Tool

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

IdentificationIdentification

Specifications

EK22GL

1. Housing

2. Retract Button

3. Battery Cartridge

4. Trigger

5. Battery Load Display

6. Locking Flange

7. Die Release Buttons

8. W-type Die Detents

9. Crimping Dies

10. Crimping Head

11. Oil Reservoir

12. Oil Plug

Crimping Tool

Length ........................................................................................... 314 mm (12-3/8")

Width........................................................................................................76 mm (3")

Height ........................................................................................... 298 mm (11-3/4")

Mass/Weight (with battery) ................................................................. 4.4 kg (9.7 lb)

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

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

Motor Type....................................................................... DC permanent field motor

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

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

Crimping Capacities

Maximum Cable Size ................................... 600 kcmil copper; 350 kcmil aluminum

Maximum Crimping Force................................................................55 kN (6.2 tons)

Average Crimps per Charge ........................................................ approximately 120

Battery

Charging Voltage ............................................................................................... 12 V

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

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Operation

Charging the Battery

Read the instructions supplied with the battery charger.

Battery Condition

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.

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.

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 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.

• Protect the crimping tool from rain and moisture.

Water will damage the crimping tool and battery.

•Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

Battery Load Display Battery Condition

Momentary illumination at Normal or operating

beginning of crimp charge level

Flickering at point of Normal or operating

maximum crimping force charge level

Flickering during entire Low charge level

crimping cycle

Constant illumination when Low charge level

operating without a load

Installing K22, KA22, and KC22-type Dies

1. Select the proper dies for the intended crimp.

2. Push the die release button.

3. Slide the die into the crimping head until it “snaps”

into place.

4. Properly position the second die. Repeat Steps

2 and 3.

Installing W-type Dies

1. Push the die release button.

2. Slide the die adapter (Greenlee part number

500 4292.0) into crimping head until it “snaps”

into place.

Note: The die adapters have the “D

” die profile.

No additional dies are needed if the connector to be

crimped requires a “D

” die.

3. Repeat for the other adapter.

4. Select the proper dies for the intended crimp.

5. Press the locking flange and open the crimping

head.

6. Push the W-type die detent and slide the W-type die

into place.

7. Properly position the second die. Repeat Steps

5 and 6.

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Operation (cont’d)

Preparing Cable

Follow the lug manufacturer’s instructions for appropriate

cable strip length.

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

SIDE B

Crimping Cable

1. Press the locking flange and open the crimping

head.

2. Insert the properly assembled connector into the

crimping head.

3. Close the crimping head.

4. Pull the trigger to make the crimp.

5. Hold the trigger down until the crimping tool

achieves pressure relief.

Notes: Pressure relief occurs at approximately

690 bar (10,000 psi) and is accompanied by an

audible “pop”.

It is normal for the battery load display to light at

both the beginning and near the end of the crimping

cycle.

An incomplete crimp can cause a fire.

•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.

6. The crimping tool returns automatically.

7. Position the crimping tool for next crimp. Repeat

Steps 4 through 6 for the number of crimps as

described in this manual.

8. Open the crimping head and remove the connector.

Notes: 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.

After completing the last crimp with W-type dies on an

aluminum connector, wipe off the excess oxide inhibitor.

Pull trigger to crimp

Push to retract ram

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Die Selection

Crimps made on copper cable with Greenlee KC22-type dies and the copper connectors listed here are

cUL and UL classified.

Crimps made on copper or aluminum cable with Greenlee KA22-type dies and the dual-rated aluminum 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.

W-type or X-type dies can be used to crimp 8 AWG to 500 kcmil copper and 8 AWG to 4/0 AWG aluminum.

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 54504–54520 BCU A

Splice Long VHS CU YS CTL SCL/SCH 54804–54820 BBCU B

Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54104–54120 BLU A

Copper YA/YA-L-TC/YA-L-2TC LCD 54204–54218

Lugs Long VHCL CTL-L/LCN YA-2N CRA-L/CRB-L LCB/LCC 54930BE–54920BE BBLU B

CRA-2L/CRB-2L 54850BE–54878BE

Catalog UPC Cable Color

Number Number Size Code

KC22-8 03079 8 AWG Red

KC22-6 03080 6 AWG Blue

KC22-4 03081 4 AWG Gray

KC22-2 03082 2 AWG Brown

KC22-1 03083 1 AWG Green

KC22-1/0 03084 1/0 AWG Pink

KC22-2/0 03085 2/0 AWG Black

KC22-3/0 03086 3/0 AWG Orange

KC22-4/0 03087 4/0 AWG Purple

KC22-250 03088 250 kcmil Yellow

KC22-300 03089 300 kcmil White

KC22-350 03090 350 kcmil Red

KC22-400 03091 400 kcmil Blue

KC22-500 03092 500 kcmil Brown

KC22-600 03093 600 kcmil Green

Connector Selection

Tool Range: Copper — 8 AWG to 600 kcmil; Dual-rated Aluminum — 8 AWG to 350 kcmil

When used with KC22-type dies, this tool is cUL and UL classified for use with the following connector brands:

Dies for Copper Connectors Dies for Dual-rated Aluminum Connectors

Catalog UPC Cable

Number Number Size

KA22-8 06744 8 AWG

KA22-6 06745 6 AWG

KA22-4 06746 4 AWG

KA22-2 06747 2 AWG

KA22-1 06749 1 AWG

KA22-1/0 06750 1/0 AWG

KA22-2/0 06751 2/0 AWG

KA22-3/0 06752 3/0 AWG

KA22-4/0 06753 4/0 AWG

KA22-250 06754 250 kcmil

KA22-300 06755 300 kcmil

KA22-350 06756 350 kcmil

Connector Barrel Anderson Blackburn®FCI Burndy Ilsco Panduit T&B Penn- No. of

Type Type Union Crimps*

Dual-rated

Aluminum — VACS ASP YS-A AS SA 60501–60565 PIK C

Splice **

Dual-rated YA-A ACL/ACN LAA/LAB 60101–60166

Aluminum — VACL ATL BLUA C

Lugs YA-ATN 2ACL/2ACN ** 60230–60267

When used with KA22-type dies, this tool is cUL and UL classified for use with the following connector brands:

*Use the number of crimps listed in the last column instead of the number provided with the connector:

95R7

C — 8 to 2 AWG: 2 crimps

1 to 3/0 AWG: 3 crimps

4/0 AWG to 350 kcmil: 4 crimps

B — 8 to 1/0 AWG: 2 crimps

2/0 to 3/0 AWG: 3 crimps

4/0 AWG to 600 kcmil: 4 crimps

A — 8 to 1/0 AWG: 1 crimp

2/0 AWG to 600 kcmil: 2 crimps

** 6 AWG to 350 kcmil

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 94455 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.

Do not use solvents or flammable

cleaners to clean the tool body.

Solvents could ignite, causing

serious injury or property damage.

After use:

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

mild detergent.

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

case. Store in a cool, dry place.

3. Charge the battery.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

3. Oil the bolt joints.

Annually or After 10,000 Crimps

1. Change the hydraulic oil.

2. Return the tool to an authorized Greenlee service

center for inspection.

Checking the Oil Level

1. Remove the two screws holding the tank housing

cover.

2. Remove the tank housing cover.

3. Point the cutting head towards the ground and

remove the oil plug. Add oil if necessary.

4. Replace the oil plug and the tank housing cover.

Secure with screws.

Recommended Hydraulic Oils

AVIA®HVI 15

Shell Tellus T 15

Mobil®DTE 11M

NUTO®H 15

EK22GL Battery-powered, High-speed Crimping Tool

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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.

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

of tool.

Crimping tool battery contacts Reform contacts.

damaged.

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.

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.

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

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