Textron Greenlee GATOR EK1240KLX Bedienungsanleitung

OPERATION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK1240KLX

GATOR®Battery-powered,

Crimping Tool

Serial Number

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

EK1240KLX Battery-powered Crimping Tool

Description

EK1240KLX Crimping Tool is a hand-held, self-con-

tained, battery-powered tools intended to crimp alumi-

num and copper connectors onto electrical cable.

The tool accepts Kearney-style dies for crimping various

types of connectors onto 8 AWG to 750 kcmil wire.

The tool has a retraction stop feature which allows the

operator to stop the retraction motion of the ram to

shorten cycle time.

The tool has a Bluetooth®connectivity and an LCD

screen.

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

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

Model X-EK1240KLX—FCC ID: 2AGL2X; IC ID:

20646X

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:

• EK1240KLX 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.

Bluetooth is a registered trademark of Bluetooth SIG, Inc.

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

LCD Screen ................................................................... 8

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

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

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

EK1240KLX 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

EK1240KLX Battery-powered Crimping Tool

IMPORTANT SAFETY INFORMATION

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 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 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.

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

EK1240KLX Battery-powered Crimping Tool

Identiﬁcation

Speciﬁcations

Crimping Tool

Length ...............................................................................................16.9" (429 mm)

Width...................................................................................................3.00" (76 mm)

Height................................................................................................12.9" (328 mm)

Weight ................................................................................................15.4 lb (7.0 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 (10 mm2to 400 mm2)

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

with the battery charger

1. LED Work Light (white)

2. Crimping Head

3. Die Release Set Screw

4. Lanyard Ring

5. Housing

6. Retract Button

7. LED Indictor (red)

8. LCD Screen

9. Battery

10. Trigger

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

EK1240KLX Battery-powered Crimping Tool

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 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

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

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

EK1240KLX 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.

Procedure

1. Clean the die seat area.

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

3. Insert one of the die halves into the ram by pressing

the die stem into the hole located in the ram.

4. Insert the other die half into the C-head by press-

ing the die stem into the hole located in the C-head.

The die half can then be locked in place by tighten-

ing the lock screw.

5. Follow the connector manufacturer’s instructions

for appropriate cable strip length and surface

preparation.

6. Insert cable fully into connector and center the

connector between the dies.

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

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.

”

8. After achieving pressure relief, the ram automatically

returns to the start position and the dies retract.

9. To stop the ram from retracting fully, activate the

trigger for a brief moment. This activation will close

the refraction valve and stop retraction motion.

10. Complete the number of crimps specied by the

connector manufacturer.

11. Remove connector from crimper.

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 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

EK1240KLX 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

EK1240KLX 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.

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

EK1240KLX Battery-powered Crimping Tool

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.

Problem Possible Cause Probable Remedy

Tool is inoperative. Battery charge low. Charge or replace battery.

Dirt, contaminants, etc., in

ram area oftool.

Clean tool.

Tool components worn or

damaged.

Contact Greenlee customer service at

800-435-0786 for warranty service or repair.

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. Contact Greenlee customer service at

800-435-0786 for warranty service or repair.

Motor runs but tool will not

complete a cycle.

Oil level low. Contact Greenlee customer service at

800-435-0786 for warranty service or repair.

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

ously. Run for approximately 10 seconds, and then

attempt to crimp. If unsuccessful, contact Greenlee

customer service at 800-435-0786 for warranty

service or repair.

Cold oil. Pull trigger and hold retract button simultaneously

to warm oil. Store tool in warm area.

Tool loses oil. Damaged seal. Contact Greenlee customer service at

800-435-0786 for warranty service or repair.

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