Textron GREENLINE GATOR EK6IDL Bedienungsanleitung

OPERATION MANUAL

GATOR®EK6IDL

Battery-powered

Dieless Crimping Tool

Serial Number

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK6IDL Battery-powered Dieless Crimping Tool

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

Description

The EK6IDL Battery-powered, High-speed Dieless

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

tool intended to crimp copper cable.

This tool is 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.

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:

EK6IDL 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 improve-

ments 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

cUL and UL Classied Crimps ................................... 8–9

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

Maintenance................................................................. 10

Troubleshooting............................................................ 11

EK6IDL 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 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.

EK6IDL 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

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 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 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

EK6IDL 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........................................................................................................ 15.75" (400 mm)

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

Depth........................................................................................................... 4.50" (114 mm)

Weight................................................................................................................ 6.6 lb (3 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

1. Indenter

2. Head

3. Latch

4. Retract Button

5. LED Indicator (red)

6. Battery Lock

7. Battery Cartridge

8. LED Work Light (white)

9. Trigger

52047087 120 VAC corded adapter

52047088 230 VAC corded adapter

52049190 18 V, 1.5 Ah lithium-ion battery

52049189 18 V, 3.0 Ah lithium-ion battery

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

52049201 120 VAC, 18 V charger

52049202 230 VAC, 18 V charger

52049204 12 VDC, 18 V charger

EK6IDL Battery-powered Dieless Crimping Tool

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

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

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

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.

EK6IDL 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.

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)

EK6IDL 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 EK6IDL Dieless Crimping

Tool 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

11111

* When crimping with the EK6IDL 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

EK6IDL Battery-powered Dieless Crimping Tool

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

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

EK6IDL 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

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.

Warranty Claims

Send tool to Greenlee CTSC Service Center.

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