Greenlee GATOR EK6IDLX Bedienungsanleitung

OPERATION MANUAL

Serial Number

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK6IDLX, EK6IDCLX

GATOR®Battery-powered

Dieless Crimping Tool

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless Battery-powered Crimping Tool

Description

The EK6IDLX, EK6IDCLX Battery-powered, High-speed

Dieless Crimping Tool is a hand-held, self-contained

crimping tools intended to crimp copper cable.

This tool has Bluetooth®connectivity and an LCD

screen.

These tools are 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—FCC ID: RFRMS42; IC ID:

4957A-MS42

USA requirements:

Responsible party: Greenlee Tools, Inc.

Rockford, IL 61109 USA

Note: This equipment has been tested and found to

comply with the limits for a Class A digital device,

pursuant to Part 15 of the FCC Rules. These limits are

designed to provide reasonable protection against

harmful interference when the equipment is operated in

a commercial environment. This equipment generates,

uses, and can radiate radio frequency energy and, if not

installed and used in accordance with the instruction

manual, may cause harmful interference to radio com-

munications. Operation of this equipment in a residential

area is likely to cause harmful interference in which case

the user will be required to correct the interference at

his own expense.

This device complies with the RF exposure SAR

test exclusion requirements for portable devices, if a

minimum separation distance is kept. However, the

device shall be used in such a manner that the potential

for human contact during normal operation is minimized.

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

cUL and UL Classied Crimps

and Connector Table .................................................. 8–9

LCD Screen .................................................................. 10

Maintenance................................................................. 11

Troubleshooting............................................................ 12

All specications are nominal and may change as design

improvements occur. Greenlee Tools, Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

GATOR is a registered trademark of Greenlee Tools, Inc.

Bluetooth is a registered trademark of Bluetooth SIG, Inc.

Blackburn is a registered trademark of Thomas & Betts.

Canada requirements:

This device complies with Industry Canada’s license-

exempt RSSs. Operation is subject to the following two

conditions:

(1) This device may not cause interference; and

(2) This device must accept any interference, including

interference that may cause undesired operation of the

device.

Le présent appareil est conforme aux CNR d’Industrie

Canada applicables aux appareils radio exempts de

licence. L’exploitation est autorisée aux deux conditions

suivantes:

1) l’appareil ne doit pas produire de brouillage;

2) l’utilisateur de l’appareil doit accepter tout brouillage

radioélectrique subi, même si le brouillage est suscep-

tible d’en compromettre le fonctionnement.

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:

• EK6IDLX Battery-powered Dieless Crimping Tool

• EK6IDCLX Battery-powered Dieless 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.

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless 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 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

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 Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless 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 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 Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless Battery-powered Crimping Tool

Identiﬁcation

Speciﬁcations

Crimping Tool

Length........................................................................................................ 16.18" (411 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)

Crimping Capacities

Maximum Cable Size

Copper......................................................................................................... 600 kcmil

Aluminum..................................................................................................... 350 kcmil

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

with the battery charger

Battery Technology ........................................................................MAKITA®LXT®Lithium ion

BL1815, BL1820, BL1830, BL1840, BL1850

1. Indenter

2. Head

3. Latch

4. Retract Button

5. LCD Screen

6. Battery Cartridge

7. LED Indicator (red)

8. Lanyard Ring

9. LED Work Light (white)

10. Trigger

MAKITA is a registered trademark of Makita Corporation.

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless Battery-powered Crimping Tool

Operation

Inspect tool 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

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 Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless Battery-powered Crimping Tool

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.

Preparation

For a cUL or UL classied crimp, refer to the

“Connector Table” in this instruction manual.

1. Select a proper size and type of connector to

correspond with the wire or cable.

2. Strip the cable to an appropriate length. Follow the

connector manufacturer’s instructions.

Note: Apply an oxide inhibitor, if required.

Refer to the connector manufacturer’s instructions.

Crimping

1. Insert the cable fully into the connector.

2. Place the connector into the V of the crimping head,

as shown below.

Connector

3. If open, close the crimping head. Make sure the

head and latch are fully engaged.

4. For a cUL or UL classied crimp, complete the

number of crimps specied in the “Connector Table”

in this manual.

5. For a single crimp, position the connector so the

crimp will be located at the center of the barrel.

6. Depress the trigger to advance the indenter. Hold

the trigger down until the indenter automatically

begins to retract.

Note: If the crimping tool does not automatically

retract, the crimp is incomplete.

It is normal for the battery load display to light at

both the beginning and near the end of the crimping

cycle.

7. Release the trigger until the indenter retracts

completely.

8. To stop the ram from returning fully, activate the

trigger for a brief moment. This activation will close

the retraction valve and stop the retraction motion.

9. Lift the latch to open the crimping head and remove

the connector.

Note: If it is necessary to retract the indenter before

a crimp cycle is complete, push the retract button.

Pushing the retract button will result in complete

retraction of the indenter.

An incomplete crimp can cause a re.

• Use proper 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.

Operation (cont’d)

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless Battery-powered Crimping Tool

cUL and UL Classiﬁed Crimps

Crimps made with the Greenlee EK6IDLX and EK6IDCLX

Dieless Crimping Tools are cUL and UL classied on

standard concentric, compressed, or compact stranded

copper cable with the connectors listed here.

Refer to the

“Connector Table”

for the brand names

and model numbers of appropriate connectors and the

number of crimps required.

Connector Table

COPPER

Connector Type **

Anderson Blackburn® Burndy ILSCO Panduit T & B

Penn-

Union **

Tyco (AMP)

Copper Splices VHSS

VHS

CSP

YS-L

CTL

SCSS

SCS

SCL, SCH

54506 to 54528

54806 to 54828

BCU

BBCU

1-1443402-5 to

1-1443403-5

Copper Lugs VHCS

VHCL

CTL

CTL-L

LCN

YA, YA-L, YA-2L

YA-2LN, YA-2N

YA-L-TC, YA-L-2TC

YA-2TC, YAZ

YAZ-2N, YAZ-2TC

CLN, CLW, CSW

CRA, CRB, CRC

CRA-L, CRB-L

CRA-2L, CRB-2L

CRC-2L

LCAS

LCA, LCB

LCD, LCC

LCAN

54106 to 54128

54206 to 54228

54906BE to 54928BE

54854BE to 54882BE

BLU

BBLU

1-1099899-7

to 1-1099939-3

Number of Crimps

Cable Size:

8 AWG to 600 kcmil

1 1 1 1 1 1 1 1

ALUMINUM

Connector Type Anderson Burndy ILSCO ***

Panduit Penn-Union

Dual-Rated

Aluminum Splices VACS YS-A AS

ASN SA PIK

BCUA

Dual-Rated

Aluminum Lugs VACL YA-A

YA-A-TN

ACL, ACN

2ACL, 2ACN

ALNS, ALNN, ALND

LAA

LAB BLUA

Number of Crimps

Cable Size:

8 AWG to 350 kcmil

1 1 1 1 1

* When crimping with this crimping tool, use the

number of crimps listed in this table instead of

the number provided with the connector.

** 6 AWG to 600 kcmil

*** 6 AWG to 350 kcmil

95R7

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless Battery-powered Crimping Tool

Connector Table (cont’d)

FLEX

COPPER

Class Diesel

Locomotive Burndy ILSCO Panduit T & B Penn-Union

G H I K M

8 AWG X X X X BCU, BBCU, BLU, BBLU-8

8 AWG X X X X 8 AWG 5104BS

8 AWG XXXXX 8 AWG YA8C CS8, CL8 LCAX8 54104, 54130, 54131, 54132, 256-30695-424

6 AWG XXXX 6 AWG CS6 ,CL6, CL4, CS4

6 AWG X BCU, BBCU, BLU, BBLU-6

6 AWG X X X BCU, BBCU, BLU, BBLU-5

6 AWG XXXXX 6 AWG YA5C LCAX6 256-30695-1361, 54134, 54105, 54135, 54136,

256-30695-282, 256-30695-422

4 AWG XXXXX 4 AWG YAC3 CS3, CL3, CS2, CL2 LCAX4 54139BS, 256-30695-1362, 54138, 54106, 54139,

54140, 256-30695-233, 256-30695-264 BCU, BBCU, BLU, BBLU-3

4 AWG X X X X X 5, 4, 3 AWG LCAX4

2 AWG XXXXX 2 AWG YA1C CS1, CL1 LCAX2 54147BS, 54107, 54142-TB, 54143-TB, 54145-TBN BCU, BBCU, BLU, BBLU-1

1 AWG X X X X 1 AWG BCU, BBCU, BLU, BBLU-1/0

1 AWG XXXXX 1 AWG YA25 CS1/0, CL1/0 LCAX1 54153BS, 54108, 54147, 54148, 54150

1/0 AWG XXXXX 1/0 AWG YA26 CS2/0, CL2/0 LCAX1/0 54110BS, 54152-TB, 54153-TB, 54109,

54155-TB, 256-30695-1383 BCU, BBCU, BLU, BBLU-2/0

2/0 AWG XXXX 2/0 AWG BCU, BBCU, BLU, BBLU-3/0

2/0 AWG X BCU, BBCU, BLU, BBLU-4/0

2/0 AWG XXXXX 2/0 AWG YA27 CS3/0, CL3/0 LCAX2/0 54165BS, 54157, 54158, 54110, 256-30695-131

3/0 AWG XXX 3/0 AWG BCU, BBCU, BLU, BBLU-4/0

3/0 AWG X BCU, BBCU, BLU, BBLU-025

3/0 AWG XXXXX 3/0 AWG YA28 CS4/0, CL4/0 LCAX3/0 54170BS, 54162-TB, 54163-TB, 54111, 54165-TB

4/0 AWG X X 4/0 AWG YA29 58165BS

4/0 AWG XXX 4/0 AWG YA30

4/0 AWG X X X 5411440BS

4/0 AWG XXXXX 4/0 AWG CS250, CL250 LCAX4/0 54167, 54168, 54112, 54170, 256-30695-1174 BCU, BBCU, BLU, BBLU-030

250 kcmil X X X X 262 kcmil 54114BS

250 kcmil X X 262 kcmil BCU, BBCU, BLU, BBLU-035

250 kcmil X BCU, BBCU, BLU, BBLU-040

250 kcmil X X YA30 CS300, CL300 5411440BS

250 kcmil X X X 262 kcmil YA31 54115260BS

250 kcmil X X X X X 262 kcmil CS350, CL350 LCAX250

300 kcmil X BCU, BBCU, BLU, BBLU-045

300 kcmil X X 313 kcmil BCU, BBCU, BLU, BBLU-040

300 kcmil X X X X X 313 kcmil YA32 CS400, CL400 LCAX300 54185BS

350 kcmil X X BCU, BBCU, BLU, BBLU-045

350 kcmil X X 373 kcmil BCU, BBCU, BLU, BBLU-050

350 kcmil X X 373 kcmil YA34 58177BS

350 kcmil X X X X X 373 kcmil CS500, CL500 LCAX350

400 kcmil X 444 kcmil BCU, BBCU, BLU, BBLU-060

400 kcmil X X BCU, BBCU, BLU, BBLU-050

400 kcmil X X X 444 kcmil YA34 58177BS

400 kcmil X X X X X 444 kcmil CS600, CL600

450 kcmil X 535 kcmil BCU, BBCU, BLU, BBLU-065

450 kcmil X X BCU, BBCU, BLU, BBLU-060

450 kcmil X X X 444 kcmil YA36 58180BS

500 kcmil X 535 kcmil YA38

500 kcmil X X X BCU, BBCU, BLU, BBLU-065

500 kcmil X X X X X 535 kcmil CS650, CL650,

CS700, CL700 54122BS

Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Dieless 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

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