Greenlee GATOR EK628 Bedienungsanleitung

INSTRUCTION MANUAL

GATOR®EK628

Battery-powered

Crimping Tool

Read and understand all of the instructions

and safety information in this manual before

operating or servicing this tool.

Serialnummer

EK628 Battery-powered Crimping Tool

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

Description

The EK628 Battery-powered Crimping Tool is a hand-

held, self-contained crimping tool with removable

crimping jaws.

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:

EK628 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 is a registered trademark of Greenlee Textron Inc.

Blackburn is a registered trademark of Thomas & Betts.

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

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

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

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

Troubleshooting......................................................... 9

Illustrations ........................................................ 10–11

Parts List ................................................................. 12

EK628 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 infor-

mation for preventing 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 operat-

ing 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, and the ram will retract. 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.

•

Keep hands away from the crimp-

ing head when crimping.

Failure to observe this warning

could result in severe injury or

death.

EK628 Battery-powered Crimping Tool

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

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.

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.

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.

This tool may be used in damp or wet environ-

ments, however, we recommend air drying the

tool before use if it becomes soaked. Damage

may result when the tool is operated prior to

drying out when electrical components are

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

EK628 Battery-powered Crimping Tool

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

Speciﬁcations

Crimping Tool

Length..................................................................................................... 465 mm (18-1/4")

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

Depth .......................................................................................................... 98 mm (3-7/8")

Mass/Weight (with battery) ............................................................................2.5 kg (5.5 lb)

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

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

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

Recommended Operating Temperature Range..........-15 °C (5 °F) through 50 °C (120 °F)

Crimping Capacities

Maximum Crimping Force ........................................................................ 53.4 kN (6 tons)

Average Crimping Time ......................................................................................4 seconds

Average Crimps per Charge ....................................................................approximately 70

Battery

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

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

1. Lock Pin

2. Crimping Jaws

3. Retract Button

4. Battery Lock

5. Battery Cartridge

6. Trigger

7. Crimping die release

8. LED Display

Identiﬁcation

EK628 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 operat-

ing or servicing this tool.

Failure to wear eye protection could

result in serious eye injury from

ying debris or hydraulic oil.

Keep hands away from the crimp-

ing head when crimping.

Failure to observe this warning

could result in severe injury or

death.

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.

This tool may be used in damp or wet environ-

ments, however, we recommend air drying the

tool before use if it becomes soaked. Damage

may result when the tool is operated prior to

drying out when electrical components are

soaked.

Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

•

Charging the Battery

Read the instructions supplied with the battery

charger.

LED Display

This tool is equipped with a special circuit board

incorporating several important features to inform

the user about the current status of the unit. The LED

signals in the following cases:

EK628 Battery-powered Crimping Tool

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

Operation (continued)

Installing Dies

1. Select the proper dies for the connector to be

crimped.

2. Install dies in jaws making certain that they are

properly secured by the spring-loaded detents.

Preparing Cable

Follow the lug manufacturer’s instructions for appro-

priate cable strip length.

Crimping Direction

First Compression

Crimping Direction

SIDE A

Crimping Direction

SIDE B

First Compression

SIDE A

First Compression

SIDE B

Crimping Procedure

1. Insert conductor into the connector and align the

tool and die on the connector. Start in the center

for splices and on the end, nearest the pad, for

terminals.

2. Activate the tool by pulling the trigger. Continue to

hold the trigger until the ram retracts. This is the

signal that the crimp is complete.

3. Continue crimping the connector until the correct

number of crimps has been completed. Work from

the center to the outer edges for splices, alternat-

ing sides if possible, for the best compression

connections.

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, and the ram will retract. 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.

•

EK628 Battery-powered Crimping Tool

Greenlee / A Textron Company 4455 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 classied.

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

connectors listed here are cUL and UL classied.

Refer to “Connector Selection” below for brand names and model numbers of appropriate lugs as well as

crimping instructions.

Dies for Copper Connectors

Catalog

Number

UPC

Number

Cable

Size

Color

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

KC22-600B 03094 600 kcmil Green

Dies for Dual-rated Aluminum Connectors

Catalog

Number

UPC

Number

Cable

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 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 classied for use with the following connector brands:

Connector

Type

Barrel

Type Anderson Blackburn® FCI Burndy Ilsco Panduit T&B Penn-

Union†

No. of

Crimps*

Copper

Splice

Short VHSS CSP YS-LsCT SCSS/SCS 54504–54518 BCU

Long VHS CU YSsCTL SCL/SCH 54804–54818 BBCU

Copper

Lugs

Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L

YA/YA-L-TC/YA-L-2TC CRA/CRB LCAS/LCA

LCD

54104–54118

54204–54218 BLU

Long VHCL CTL-L/LCN YA-2N CRA-L/CRB-L

CRA-2L/CRB-2L LCB/LCC 54930BE–54918BE

54850BE–54876BE BBLU

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

Connector

Type

Barrel

Type Anderson Blackburn® FCI Burndy Ilsco Panduit** T&B Penn-

Union

No. of

Crimps*

Dual-rated

Aluminum

Splice

– VACS ASP YS-A AS SA 60501–60565 PIK

Dual-rated

Aluminum

Lugs

– VACL ATL YA-A

YA-ATN

ACL/ACN

2ACL/2ACN LAA/LAB 60101–60166

60230–60267 BLUA

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

A — 8 to 1/0 AWG: 1 crimp

2/0 AWG to 600 kcmil: 2 crimps

B — 8 to 2 AWG: 2 crimps

1 to 3/0 AWG: 3 crimps

4/0 AWG to 350 kcmil: 4 crimps

** 6 AWG to 350 kcmil

† 500 kcmil maximum with Penn-Union connectors

s8 AWG to 350 kcmil with Burndy copper splices

95R7

EK628 Battery-powered Crimping Tool

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

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 display 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.

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

1. Thoroughly clean all surfaces.

2. Oil the pin joints.

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.

EK628 Battery-powered Crimping Tool

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

55 50

30 31

34 35

36 37

Motor Assembly

Pump Housing Unit, Relief Valve Unit,

and Piston Pump Assembly

7 6

Illustrations

Main

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