Textron EK12IDL Bedienungsanleitung

OPERATION MANUAL

GATOR®EK12IDL

Battery-powered,

Dieless Crimping Tool

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK12IDL Battery-powered, Dieless Crimping Tool

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

Description

The EK12IDL Battery-powered, High-speed Crimping

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

intended to crimp aluminum and copper connectors

onto electrical cable.

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:

EK12IDL 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.

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.

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

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

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

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

EK12IDL Battery-powered, Dieless 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 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.

EK12IDL Battery-powered, Dieless Crimping Tool

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

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.

IMPORTANT SAFETY INFORMATION

EK12IDL Battery-powered, Dieless Crimping Tool

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

Identiﬁcation

Speciﬁcations

Crimping Tool

Length ............................................................................................16.5" (419.1 mm)

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

Height (with battery) .......................................................................14.5" (368.3 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

Aluminum............................................................................ 6 AWG to 1000 kcmil

Copper................................................................................ 4 AWG to 1000 kcmil

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

with the battery charger

1. LED Work Light (white)

2. Indenter

3. Head

4. Latch (for opening head)

5. Lanyard Ring

6. Housing

7. Retract Button

8. LED Indicator (red)

9. Battery

10. Trigger 10

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

EK12IDL Battery-powered, Dieless Crimping Tool

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.

EK12IDL Battery-powered, Dieless Crimping Tool

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

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.

For a double crimp, position the connector so two

crimps will be evenly spaced between the connec-

tor marks.

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.

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.

Automatic Retraction Stop

1. Depress the trigger to advance the indenter. Hold

the trigger down until the indenter automatically

retracts. The indenter will partially retract to allow

the tool to be repositioned.

2. If full retraction is desired, release the trigger at the

end of the crimp.

Operation (cont’d)

EK12IDL Battery-powered, Dieless Crimping Tool

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

cUL and UL Classiﬁed Crimps

Crimps made with the Greenlee EK12IDL Dieless

Crimping Tool are cUL and UL classied on standard

concentric, compressed, or compact stranded copper

and aluminum 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

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

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 —

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

1099898-2 to

1-1099898-5

1099899-2 to

1-1099899-9

1099939-1 to

1-1099939-5

*Number of

Crimps

Copper Cable Size:

4 AWG–1000 kcmil 1 1 1 1 1 1 1 1

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

Union

Dual-Rated Aluminum Splices VACS ASP YS-A AS, ASN SA 60507 to 60584 PIK

BCUA

Dual-Rated Aluminum Lugs VACL ATL YA-A

YA-A-TN

ACL, ACN

2ACL, 2ACN

ALNS, ALNN

ALND

LAA

LAB

60106 to 60184

60230 to 60284 BLUA

*Number of

Crimps

Cable Size: 6 AWG–500 kcmil 1 1 1 1 1 1 1

Cable Size: 600 kcmil–800 kcmil 2 1 1 1 2 1 1

Cable Size: 1000 kcmil 2 2 2 2 2 2 2

* When crimping with the EK12IDL crimping tool, use the number of crimps listed in this table

instead of the number provided with the connector.

EK12IDL Battery-powered, Dieless Crimping Tool

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.

EK12IDL Battery-powered, Dieless Crimping Tool

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

simultaneously. 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

simultaneously 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

simultaneously. 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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