Textron EK1240L Bedienungsanleitung

OPERATION MANUAL

GATOR®

EK1240L and EK1240CL

Battery-powered

Crimping Tools

Serial Number

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK1240L and EK1240CL Crimping Tools

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

KEEP THIS MANUAL

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.

Blackburn is a registered trademark of Thomas & Betts.

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........................................................... 10

Description

The EK1240L Crimping Tool is a hand-held,

self-contained, battery-powered tool intended to crimp

aluminum and copper connectors onto electrical cable.

The EK1240CL has a PVC-covered crimping head.

This tool has a retraction stop feature which allows the

operator to stop the retraction motion of the ram to

shorten cycle time.

This tool is protected by U.S. Patent No. 6,206,663,

6,276,186, 6,401,515, and 6,718,870.

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:

EK1240L Battery-powered Crimping Tool

EK1240CL Battery-powered Crimping Tool

with PVC-covered Head

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.

EK1240L and EK1240CL Crimping Tools

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 on or 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. Oil under pressure easily

punctures skin. If injured, seek

medical attention immediately to

remove oil.

Failure to observe this warning

could result in serious injury, gan-

grene, 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 combina-

tions. 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.

EK1240L and EK1240CL Crimping Tools

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

IMPORTANT SAFETY INFORMATION

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 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.

• Carrying strap is for carrying only, not to be used

to hang or suspend tool.

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.

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 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.

EK1240L and EK1240CL Crimping Tools

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

Identiﬁcation

Speciﬁcations

Crimping Tool

Length ..........................................................................................16.25" (412.7 mm)

Width................................................................................................2.87" (72.9 mm)

Height...........................................................................................12.50" (317.5 mm)

Weight ...................................................................................................15 lb (6.8 kg)

Crimping Force................................................................................ 12 tons (106 kN)

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

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

Crimping Capacities

Crimping Range ........................................................................ 8 AWG to 750 kcmil

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

with the battery charger

EK1240L and EK1240CL

1. LED Work Light (white)

2. Head

3. Die Release Buttons

4. Lanyard Ring

5. Housing

6. Retract Button

7. LED Indictor (red)

8. Battery

9. Trigger

52047087 120 VAC corded adapter

52047088 230 VAC corded adapter

52049189 18 V, 3 Ah lithium-ion battery

52049201 120 VAC, 18 V charger

52049202 230 VAC, 18 V charger

52049204 12 VDC, 18 V charger

52054992 Li (18 V) to NiCd, NiMH (12 V) charger adapter

50122746 Carrying strap

EK1240L and EK1240CL Crimping Tools

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

Operation

• 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.

• Carrying strap is for carrying only, not to be used

to hang or suspend tool.

Failure to observe these warnings could result in

severe injury or death.

Electric shock hazard:

This tool is not insulated. When

using this unit on or 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:

• 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

Flashing light for 2seconds Battery is inserted in tool

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

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.

EK1240L and EK1240CL Crimping Tools

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

Operation (cont’d)

Procedure

1. Clean the die seat area.

2. Install the proper size and type of crimping dies.

3. Press the release button on the C-head and slide

one of the die halves into the jaw. Release the

button and slide the die half until the retainer snaps

and locks the die into place.

4. Press the release button on the ram body (located

in the cutout) and slide the other die half in. Release

the button and slide the die half until the retainer

snaps and locks the die into place.

Follow the connector manufacturer’s instructions for

appropriate cable strip length and surface preparation.

6. Insert cable fully into connector and center the con-

nector between the dies.

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

SIDE B

7. Using the sequence illustrated here, press the

trigger to advance the dies. Continue to crimp until

the pressure relief valve activates.

Note: Pressure relief occurs at approximately

106 kN (12 tons) and is indicated by an audible “pop.”

After achieving pressure relief, the ram automatically

returns to the start position and the dies retract.

9. 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.

10. When using KC12-type dies, complete the number

of crimps listed on the “Connector Selection” chart

in this manual. For other dies, complete the number

of crimps specied by the manufacturer.

11. Remove the connector from the crimping tool.

Note: After completing the last crimp on an aluminum

connector, wipe off the excess oxide inhibitor.

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 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.

EK1240L and EK1240CL Crimping Tools

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

Die Selection

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

Crimps made with this tool and KC12-type or KA12-type dies are cUL and UL classied when used with the appropriate

conductor and connectors listed below.

Connector Selection (NOT for use with ﬂex, navy or welding wire)

Tool Range: 8 AWG to 750 kcmil

When used with KC12-type dies, this tool is cUL and UL classied for use with the following connector brands:

When used with KA12-type dies, this tool is cUL and UL classied for use with the following connector brands:

* Use the number of

crimps listed in this

column instead of the

number provided with

the connector.

Short

Long

Short

Long

BARREL

TYPE

8 AWG to

250 kcmil:

1 crimp

300 to

750 kcmil:

2 crimps

NUMBER

OF CRIMPS*

VHSS

VHS

VHCS

VHCL

ANDERSON

CSP

CTL-2/CTL

CTL-L/LCN

BLACKBURN®

YS-L

YA-2LN/

YA-L/YA-2L;

YA/YA-L-TC/

YA-L-2TC

YA/YAZ

YA-2N/YA-2TC

YAZ-2N/YAZ-2TC

BURNDY

CTL

CSW

CRA/CRB

CRC

CLN, CLW

CRA-L/CRB-L

CRA-2/CRB-2L

CRC-2L

ILSCO

SCSS

SCS

SCL

SCH

LCAS

LCA

LCD

LCAN

LCB

LCC

PANDUIT

54504 to

54523-TB

54804 to

54823

54104 to

54123-TB;

54204 to

54223

54930BE to

54923BE;

54850BE to

54880BE

T&B

BCU

BBCU

BLU

BBLU

PENN-

UNION

CONNECTOR

TYPE

Copper

Splices

Copper

Lugs

8 to

1/0 AWG:

1 crimp

2/0 AWG to

350 kcmil:

2 crimps

400 to

750 kcmil:

3 crimps

NUMBER

OF CRIMPS*

ANDERSON

VACS

VACL

BLACKBURN®

ASP

ATL

BURNDY

YS-A

YA-A

YA-ATN

ILSCO

ASN

ACL/ACN

2ACL/2ACN

ALNS/ALNN/ALND

PANDUIT

LAA

LAB

T&B

60501 to

60578

60101 to

60176;

60230 to

60278

PENN-

UNION

PIK

BLUA

CONNECTOR

TYPE

Dual-rated

Aluminum

Splices

Dual-rated

Aluminum

Lugs

95R7

Dies for Copper Connectors

Catalog

No.

UPC

No.

Cable

Size

Color

Code

No. of

Crimps

KC12-8 10996 8 AWG Red 1

KC12-6 10997 6 AWG Blue 1

KC12-4 10998 4 AWG Gray 1

KC12-2 10999 2 AWG Brown 1

KC12-1 11003 1 AWG Green 1

KC12-1/0 11004 1/0 AWG Pink 1

KC12-2/0 11007 2/0 AWG Black 1

KC12-3/0 11010 3/0 AWG Orange 1

KC12-4/0 11011 4/0 AWG Purple 1

KC12-250 11012 250 kcmil Yellow 1

KC12-300 11013 300 kcmil White 2

KC12-350 11014 350 kcmil Red 2

KC12-400 11015 400 kcmil Blue 2

KC12-500 11016 500 kcmil Brown 2

KC12-600 11018 600 kcmil Green 2

KC12-750 11020 750 kcmil Black 2

Dies for Aluminum Connectors

Catalog

No.

UPC

No.

Cable

Size

Color

Code

No. of

Crimps

KA12-8 22084 8 AWG Blue 1

KA12-6 22085 6 AWG Gray 1

KA12-4 22086 4 AWG Green 1

KA12-2 22087 2 AWG Pink 1

KA12-1 22088 1 AWG Gold 1

KA12-1/0 22089 1/0 AWG Tan 1

KA12-2/0 22090 2/0 AWG Olive 2

KA12-3/0 22121 3/0 AWG Ruby 2

KA12-4/0 22122 4/0 AWG White 2

KA12-250 22123 250 kcmil Red 2

KA12-300 22124 300 kcmil Blue 2

KA12-350 22125 350 kcmil Brown 2

KA12-400 22126 400 kcmil Green 3

KA12-500 22127 500 kcmil Pink 3

KA12-600 22128 600 kcmil Black 3

KA12-750 22129 750 kcmil Yellow 3

EK1240L and EK1240CL Crimping Tools

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

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

punctures skin. If injured, seek

medical attention immediately to

remove oil.

Failure to observe this warning

could result in serious injury, gan-

grene, 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, send the tool to a

Greenlee Authorized Service Center for inspection.

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

1. Thoroughly clean all surfaces.

2. Check the oil level.

Annually or After 10,000 Crimps

1. Replace the hydraulic oil.

2. Send the tool to a Greenlee Authorized Service

Center for inspection.

Checking the Oil Level

1. Remove the screws holding the housing cover

together.

2. Point the crimping head downward and remove the

oil reservoir plug. Fill reservoir if necessary.

3. Replace the oil plug and housing cover.

Note: For Warranty Service or Repair, contact Greenlee

customer service at 800-435-0786.

EK1240L and EK1240CL Crimping Tools

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

Problem Possible Cause Probable Remedy

Tool is inoperative. Dirt, contaminants, etc.,

in ram area oftool.

Clean tool.

Tool battery contacts damaged. Reform contacts.

Tool components worn or

damaged.

Return tool to a Greenlee Authorized Service

Center.

Motor is inoperative. Low or uncharged battery. Try known charged battery. Inoperative battery

may be discharged or may have reached life

expectancy.

Broken switch components. Return tool to a Greenlee Authorized Service

Center.

Motor runs but tool will not

complete a cycle.

Oil level low. Return tool to a Greenlee Authorized Service

Center.

Air in hydraulic system. Pull trigger and hold retract button simultane-

ously. Run for approximately 10 seconds, and

then attempt to crimp. If unsuccessful, return

tool to a Greenlee Authorized Service Center.

Cold oil. Pull trigger and hold retract button simultane-

ously to warm oil. Store tool in warm area.

Dies stop during operation. Oil level low. Return tool to a Greenlee Authorized Service

Center.

Air in hydraulic system. Pull trigger and hold retract button simultane-

ously. Hold for approximately 10 seconds.

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

Tool loses oil. Damaged internal seal. Return tool to a Greenlee Authorized Service

Center.

Note: For Warranty Service or Repair, contact Greenlee customer service at 800-435-0786.

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 tool.

3. Reinstall the battery and check the tool again.

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