Textron EK1550L Bedienungsanleitung

OPERATION MANUAL

GATOR®EK1550L

Battery-powered

Crimping Tool

Serial Number

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK1550L Battery-powered Crimping Tool

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

Description

The EK1550L Battery-powered, High-speed Crimping

Tool is a hand-held, self-contained 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:

EK1550L 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.

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

Adapter Kits................................................................ 6–8

Setup .............................................................................. 8

Operation.................................................................. 9–10

Die Selection ................................................................ 11

Connector Selection..................................................... 11

Maintenance................................................................. 12

Troubleshooting............................................................ 13

EK1550L 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 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.

EK1550L Battery-powered Crimping Tool

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.

EK1550L Battery-powered Crimping Tool

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

Identiﬁcation

Crimping Tool

Length .....................................................19.5" (495.3 mm)

Width .........................................................3.00" (76.2 mm)

Height (with battery)..............................12.25" (311.2 mm)

Mass/Weight (with battery) .....................21.25 lb (9.63 kg)

Crimping Force ........................................ 15 tons (135 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

Speciﬁcations

1. LED Work Light (white)

2. Die Release Button

3. Crimping Head

4. Lanyard Ring

5. Housing

6. Retract Button

7. LED Indictor (red)

8. Battery

9. Trigger

Crimping Capacities

Maximum Crimping Capacity

Aluminum..................................................... 1250 kcmil

Copper......................................................... 1500 kcmil

*With PH14 Dies (no Adapter Kit needed):

1027 kcmil 48/7 ACSR

*With 48824 Die Holder Kit for PH2 Dies:

477 26/27 ACSR tension,

terminals through 1033 kcmil

With 48788 Die Holder Kit for TBM 15 Dies:

1000 kcmil copper and aluminum ttings

With 48820 Die Holder Kit for Y46 Dies:

1250 kcmil aluminum and

1500 kcmil copper ttings

With 48802 Die Holder Kit for 12-ton “U” Dies:

500 kcmil copper splices,

750 kcmil copper terminals,

350 kcmil aluminum splices,

750 kcmil aluminum terminals

* Do not use non-butting dies (crimps controlled by

tonnage) in this tool, as damage could occur to

connectors and/or conductors.

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

EK1550L Battery-powered Crimping Tool

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

Procedure for Using Kearney PH14 Dies

1. No die holder assemblies are needed. Dies t

directly into tool.

2. Select proper die set for tting to be crimped.

Note: Do not use non-butting dies (crimps con-

trolled by tonnage) in this tool, as damage could

occur to connectors and/or conductors.

3. Install upper die in hole in top of “C” head. Snap in

place with top die retaining plunger (6).

4. Install lower die in hole in end of piston. Snap in

place with bottom die retaining plungers (6).

Adapter Kits

Procedure for Using Kearney PH2 Dies;

48824 Die Holder Kit

1. Install 48823 PH2 die spacer assembly into hole

in top of “C” head. Snap in place with retaining

spring plunger (6).

2. Install upper 48825 die holder assembly into hole in

die spacer assembly. Lock in place with die spacer

retaining screw.

3. Install lower 48825 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

4. Select proper die set for tting to be crimped.

Note: Do not use non-butting dies (crimps con-

trolled by tonnage) in this tool, as damage could

occur to connectors and/or conductors.

5. Slide die into place in top die holder tight against

shoulder. Detent screw will snap into groove of

die. Lock in place with top die retaining cap screw.

Repeat operation for other die entry.

PH2 Die Holder Kit 48824 contains:

(1) 48823 and (2) 48825 Die Holders

PH14 DIES

BOTTOM DIE

RETAINING SPRING

PLUNGERS (6)

TOP DIE HOLDER

RETAINING SPRING PLUNGER (6) TOP DIE HOLDER

RETAINING SPRING PLUNGER (6)

48823 PH2

DIE SPACER

ASSEMBLY DETENT SCREWS

TOP DIE

RETAINING SCREW

48825 PH2

DIE HOLDER ASSEMBLIES

BOTTOM DIE

RETAINING SCREW

TOP DIE HOLDER

RETAINING SCREW

BOTTOM DIE HOLDER

RETAINING SPRING PLUNGERS (6)

EK1550L Battery-powered Crimping Tool

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

Adapter Kits (cont’d)

Procedure for Using Thomas & Betts TBM15 Dies;

48788 Die Holder Kit

1. Install the upper 48789 die holder assembly in hole

in top of “C” head. Snap in place with top die holder

retaining spring plunger (6).

2. Install lower 48789 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

3. Select proper die set for tting to be crimped.

4. Slide top die into place in die holder while depress-

ing die retainer button. Release die button while it

snaps into place, locking die into position. Repeat

operation for other die entry.

Procedure for Using Burndy Y46 Dies;

48820 Die Holder Kit

1. Install the upper 48822 die holder assembly in hole

in top of “C” head. Snap in place with top die holder

retaining spring plunger (6).

2. Install lower 48821 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

3. Select proper die set for tting to be crimped.

4. Slide top die into place in die holder while simulta-

neously squeezing both retainer buttons. Release

buttons and allow them to snap into place. Repeat

operation for other die entry.

48788 Die Holder Kit contains:

(2) 48789 Die Holders

48820 Die Holder Kit contains (1) each:

48822 Upper Die Holder and 48821 Lower Die Holder

48789 TBM15 DIE

HOLDER ASSEMBLIES

BOTTOM DIE

HOLDER RETAINING

SPRING PLUNGERS (6)

TOP DIE

HOLDER

RETAINING

SPRING

PLUNGER (6)

BOTTOM DIE

RETAINING MECHANISM

TOP DIE

RETAINING

MECHANISM

48822 Y46 DIE

HOLDER ASSEMBLY

BOTTOM DIE

HOLDER RETAINING

SPRING PLUNGERS (6)

BOTTOM DIE

RETAINING

MECHANISM (2)

TOP DIE

RETAINING

MECHANISM (2)

TOP DIE HOLDER

RETAINING SPRING PLUNGER (6)

EK1550L Battery-powered Crimping Tool

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

Adapter Kits (cont’d)

Procedure for Using 12-Ton “U” Dies;

48802 Die Holder Kit

1. Install the upper 48803 die holder assembly in hole

in top of “C” head. Snap in place with top die holder

retaining spring plunger (6).

2. Install lower 48803 die holder assembly in hole in

end of piston. Snap in place with bottom die holder

retaining spring plungers (6).

3. Select proper die set for connector to be crimped.

4. Slide die into place in die holder while depress-

ing die retainer button. Release die button while it

snaps into place, locking die into position. Repeat

operation for other die entry.

12-Ton “U” Die Holder Kit 48802 contains:

(2) 48803 Die Holders

TOP DIE HOLDER

RETAINING SPRING

PLUNGER (6)

48803 12-TON “U”

DIE HOLDER ASSEMBLIES BOTTOM DIE HOLDER

RETAINING SPRING

PLUNGERS (6)

DIE RETAINING MECHANISMS

Setup

1. Select the die set that corresponds to the size, type,

and manufacturer of connector to be crimped.

2. Select proper die holders set for type of dies to be

used. Install the die holders and/or dies according

to procedures under “Adapter Kits”.

• Kearney PH14 dies—no holders required

• Kearney PH2 dies—48824 Die Holder Kit

• 12-ton “U” dies—48802 Die Holder Kit

• T&B TBM 15 dies—48788 Die Holder Kit

• Burndy Y46 type “P” dies—48820 Die Holder Kit

3. Install proper size crimping dies in crimping head.

Be sure die seat area is clear of debris.

4. Connect the hydraulic hose from the power source

to the tool.

5. In cold weather, allow the power source to run

(idle) for a few minutes to warm the hydraulic uid.

Actuating the tool intermittently will reduce the time

required to warm the uid to an efcient operating

temperature.

EK1550L Battery-powered 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.

EK1550L Battery-powered Crimping Tool

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

Operation (cont’d)

For a cUL or UL classied crimp, see the connector

table in this instruction manual.

Preparation

Note: 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 speciﬁed by the manufacturer.

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.

See the connector manufacturer’s instructions.

3. Clean the die seat area.

Crimping

1. Insert the cable fully into the connector.

2. Align the connector between the crimping dies as

shown below.

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

number of crimps specied under “Connector

Selection”.

4. 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.

5. Depress the trigger to advance the piston. Hold the

trigger down until the piston automatically begins to

retract.

Notes: 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.

6. Release the trigger until the piston retracts

completely.

7. 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.

Note: if it is necessary to retract the piston before

a crimp cycle is complete, push the retract button.

Pushing the retract button will result in complete

retraction of the piston.

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.

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