Greenlee GATOR EK628LX Bedienungsanleitung

OPERATION MANUAL

Serial Number

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK628LX

GATOR®Battery-powered

Crimping Tools

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

EK628LX Battery-powered Crimping Tool

Description

The EK628LX Battery-powered Crimping Tool are

hand-held, self-contained crimping tool with removable

crimping jaws.

This tool has a Bluetooth®connectivity and an LCD

screen.

The tool is protected by U.S. Patent No. 6,276,186,

6,401,515, 6,718,870, 7,086,979, 7,216,523, and

7,254,982.

Model X-EK628LX—FCC ID: 2AGL2CFM; IC ID:

20646CFM

This device complies with Part 15 of the FCC Rules and

with Industry Canada licence-exempt RSS standard(s).

Operation is subject to the following two conditions:

(1) this device may not cause harmful interference, and

(2) this device must accept any interference received,

including interference that may cause undesired

operation

Note: Change or modiﬁcations made to this equipment

not expressly approved by Greenlee may void the FCC

authorization to operate this equipment.

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.

Note: For body worn operation, this device has been

tested and meets the FCC RF exposure guidelines for

an uncontrolled environment. The maximum reported

SAR value is 0.08 mW/g

Purpose of this Manual

This manual is intended to familiarize all personnel with

the safe operation and maintenance procedures for the

following Greenlee tool:

• EK628LX Battery-powered Crimping Tool

Keep this manual available to all personnel.

Replacement manuals are available upon request

at no charge at www.greenlee.com.

Do not discard this product or throw away!

For recycling information, go to www.greenlee.com.

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

LCD Screen .................................................................... 9

Maintenance................................................................. 10

Troubleshooting............................................................ 11

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 Textron Innovations Inc.

Bluetooth is a registered trademark of Bluetooth SIG, Inc.

Blackburn is a registered trademark of Thomas & Betts.

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

EK628LX Battery-powered Crimping Tool

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 on or near energized electri-

cal lines, use proper personal protec-

tive 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. Oil under pressure easily punc-

tures skin. If injured, seek medical

attention immediately to remove oil.

Failure to observe this warning could

result in serious injury, gangrene, or

death.

Do not use solvents or ammable

liquids to clean the tool body.

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 combinations.

Improper combinations can result in an incomplete

crimp.

• The relief valve sounds and the ram automatically

retracts to indicate a completed crimp. If you do not

hear the sound of the relieve valve or the ram does

not automatically retract, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

Pinch points:

• Remove battery before changing

dies, adapters, or jaws.

• Keep hands away from the crimp-

ing tool head when crimping.

Failure to observe these warnings

could result in severe injury or death.

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

EK628LX Battery-powered Crimping Tool

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.

Remove the battery before transporting the T version

of this tool by air.

Failure to observe this warning could result in severe

injury or death.

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 use this tool for continuous use. After 30 to

40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is

designed for hand-held operation.

• This tool may be used in damp or wet environ-

ments; however, air-drying is recommended before

use if the tool becomes soaked. Damage may result

when the tool is operated prior to thorough drying

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.

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 bat-

teries 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 122 °F (50°C)

or less than –4 °F (–20 °C). 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.

IMPORTANT SAFETY INFORMATION

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

EK628LX Battery-powered Crimping Tool

Identiﬁcation

1. Lock Pin

2. Crimping Jaws

3. Crimping Die Release

4. Retract Button

5. LCD Screen

6. Battery Cartridge

7. LED Indicator (red)

8. Lanyard Ring

9. LED Work Light (white)

10. Trigger

Speciﬁcations

Crimping Tool

Length............................................................................................................. 18" (456 mm)

Width ............................................................................................................. 2.95" (75 mm)

Depth........................................................................................................... 4.92" (125 mm)

Weight............................................................................................................. 6.4 lb (2.9 kg)

Crimping Force...............................................................................................6 tons (53 kN)

Hydraulic Oil ......................................................... 52057878 biodegradable hydraulic uid

Recommended Operating Temperature Range...................5 °F to 122 °F (–15 °C to 50°C)

Battery Charger........................................................................ Read the instructions supplied

with the battery charger

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

EK628LX Battery-powered Crimping Tool

Operation

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.

Electric shock hazard:

This tool is not insulated. When using

this unit on or near energized electri-

cal lines, use proper personal protec-

tive 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:

• Remove battery before changing

dies, adapters, or jaws.

• Keep hands away from the crimp-

ing tool head when crimping.

Failure to observe these warnings

could result in severe injury or death.

• Do not use this tool for continuous use. After 30 to

40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is

designed for hand-held operation.

• This tool may be used in damp or wet environ-

ments; however, air-drying is recommended before

use if the tool becomes soaked. Damage may result

when the tool is operated prior to thorough drying

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 Work Light (white)

This LED automatically turns on when the trigger is

pulled. It remains on for 10 seconds after the trigger is

released.

LED Indicator (red)

This tool is equipped with a special circuit board incor-

porating several important features to inform the user

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

the following cases:

What happens Signal What it means

Constant light for 20seconds

at end of cycle

Battery charge is below

17V at beginning of cycle*

Tool will not start, and

constant light for 20seconds

when trigger is released

Battery charge is below

16V at beginning of cycle*

Tool will stop, and constant

light for 20seconds after

trigger is released

Battery voltage drops

below 13V during cycle*

Tool will stop, and ﬂashing

light for 20seconds when

trigger is released

Motor current exceeds

20A during cycle

Circuit has become too hot

Flashing light for 20 seconds

at end of cycle Send tool in for service

* Running the battery below 16 V can damage the battery.

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

EK628LX Battery-powered Crimping Tool

Operation (cont’d)

Pressure Sensor

This tool is equipped with a pressure sensor that alerts

the user of an incomplete crimp.

• If the tool is manually retracted before completion of a

crimp, the red LED and an audible beep will be active

for 2 seconds.

• If the tool is unable to reach the required crimp force,

the red LED, work light, and an audible beep will pulse

until after the trigger is released.

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, positive

lock, die buttons.

Preparing Cable

Follow the lug manufacturer’s instructions for appropri-

ate cable strip length.

Crimping Direction

(evenly spaced)

First Compression

Crimping Direction

SIDE A

(evenly spaced)

Crimping Direction

SIDE B

(evenly spaced)

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; start 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 combinations.

Improper combinations can result in an incomplete

crimp.

• The relief valve sounds and the ram automatically

retracts to indicate a completed crimp. If you do not

hear the sound of the relieve valve or the ram does

not automatically retract, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

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

EK628LX Battery-powered Crimping Tool

CJ22 Jaw and KA22/KC22-type Die Selection

Note: This tool will provide a cUL and UL classiﬁed crimp ONLY when used with the CJ22 jaws

and KA22- or KC22-type dies.

Note: This tool will provide 53 kN (6 tons) of crimping force when used with the CJ22 jaws.

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” for brand names and model numbers of appropriate lugs as well as crimping instructions.

95R7

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

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

Connector Selection

CJ22 Crimping Jaw 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®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

CSW

CRA/CRB

LCAS/LCA

LCD

54104-54118

54204-54218 BLU

Long VHCL CTL-L/LCN YA-2N

CLN/CLW

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®Burndy ILSCO Panduit** T&B Penn-

Union

No. of

Crimps*

Dual-rated

Aluminum Splice — VACS ASP YS-A AS

ASN SA 60501-60565 PIK

Dual-rated

Aluminum Lugs — VACL ATL YA-A

YA-ATN

ACL/ACN

2ACL/2ACN

ALNS/ALNN/ALND

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 B — 8 to 2 AWG: 2 crimps

2/0 AWG to 600 kcmil: 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

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

EK628LX Battery-powered Crimping Tool

LCD Screen

This tool has an LCD screen, which displays informa-

tion about the tool. Turn on the screen by inserting the

battery and jogging the tool. If there are any problems

with the tool, an error code appears.

Error Code Meaning

1 Overcurrent fuse

2 Overcurrent comparator

3 Overheated circuit board

4 Overheated battery

5 Battery empty; operation stops

6 Faulty crimp; complete cycle

7 Faulty crimp; incomplete cycle

8 Low battery

9 Battery empty; tool won’t run

10 Real-time clock battery low

11 Tool deactivated

12 Service necessary

13 Real-time clock not found

14 Bluetooth®unit not found

16 Pressure sensor not found

17 Burst pressure exceeded

18 Battery temperature too low

If there is no error code, cycle through the various

displays using the left and right buttons on either side of

the screen. There are seven displays in total.

Display Information Shown

1Bluetooth®status, battery charge, current

pressure, max. pressure

2Firmware, available rmware update,

serialnumber

Current user. Press and hold both buttons to

change user, select with right button, and conrm

by jogging the tool.

6 Cycles until next service

7Since manufacturing: operating hours, capacity,

number of cycles

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

EK628LX Battery-powered Crimping Tool

Maintenance

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. Oil under pressure easily punc-

tures skin. If injured, seek medical

attention immediately to remove oil.

Failure to observe this warning could

result in serious injury, gangrene, or

death.

Do not use solvents or ammable

liquids to clean the tool body.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

Pinch points:

• Remove battery before changing

dies, adapters, or jaws.

• Keep hands away from the crimp-

ing tool head when crimping.

Failure to observe these warnings

could result in severe injury or death.

Relief valve adjustments must be done by an

authorized service center.

Daily

Before use:

1. Inspect the tool for wear or damage, such as cracks,

gouges, or chips.

2. Inspect the tool for damage or leaks.

3. Inspect the rotation of the head assembly. Fully

retract the ram. The head should rotate no more

than 360°. If damage is detected, contact Greenlee

customer service at 800-435-0786 for warranty

service or repair.

After use:

1. Use a damp cloth and mild detergent to clean the

housing. Allow the housing to dry.

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

case and store in a cool, dry place.

3. If necessary, recharge the batteries. Refer to the

instructions supplied with the battery charger.

Monthly

Thoroughly clean all surfaces.

Annually or After 10,000 Crimps

Contact Greenlee customer service at 800-435-0786 for

warranty service or repair, and hydraulic oil replacement.

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