GATOR® EK06FTL Battery-powered Crimping Tool

OPERATION MANUAL
Serial Number
GATOR EK06FTL
Battery-powered
Crimping Tool
®
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
52047667 REV 4
© 2014 Greenlee Textron Inc.
3/14
EK06FTL Battery-powered Crimping Tool
Table of Contents
Description
Description..................................................................... 2
Safety............................................................................. 2
Purpose of this Manual.................................................. 2
Important Safety Information......................................3–4
Identification................................................................... 5
Specifications................................................................. 5
Operation.....................................................................6–7
Connector Selection....................................................... 8
Maintenance................................................................... 9
Troubleshooting............................................................ 10
The EK06FTL 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, and 6,401,515.
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:
EK06FTL 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 specifications 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
Greenlee / A Textron Company
2
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
flying debris or hydraulic oil.
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, defined below,
indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
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, gangrene, or death.
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.
Do not use solvents or flammable
liquids to clean the tool body.
Solvents or flammable liquids could
ignite and cause serious 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.
An incomplete crimp can cause a fire.
• 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.
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.
Greenlee / A Textron Company
3
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
IMPORTANT SAFETY INFORMATION
Pinch points:
• Remove battery before changing
dies, adapters, or jaws.
• Keep hands away from the crimping tool head when crimping.
Failure to observe these warnings
could result in severe injury or death.
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 dispose of batteries in a fire. They will vent
fumes and may explode.
Failure to observe this warning could result in severe
injury from harmful fumes or burns from flying
debris.
• 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.
• Inspect tool and dies before use. Replace any
worn or ­damaged parts. A damaged or improperly ­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 environments; 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.
Greenlee / A Textron Company
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.
4
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
Identification
3
2
EK06FTL and EK06FTCL
4
1. LED Work Light (white)
2. Crimping Head
3. Lanyard Ring
4.Housing
5. Retract Button
6. LED Indictor (red)
7.Battery
8.Trigger
6
5
1
8
7
Specifications
Crimping Tool
Length...........................................................................................14.87" (377.7 mm)
Width.................................................................................................2.87" (72.9 mm)
Height (with battery).........................................................................12.25" (311 mm)
Weight.......................................................................................................11 lb (5 kg)
Crimping Force.................................................................................. 6.2 tons (55 kN)
Hydraulic Oil................................................52057878 biodegradable hydraulic fluid
Recommended Operating Temperature Range.............. 5 °F to 122 °F (–15 °C to 50 °C)
Crimping Capacities
Crimping Range
Copper................................................................................... 4 AWG to 750 kcmil
Aluminum............................................................................... 6 AWG to 750 kcmil
Battery Charger..............................................................Read the instructions supplied
with the battery charger
52047087
120 VAC corded adapter
52049202
230 VAC, 18 V charger
52047088
230 VAC corded adapter
52049204
12 VDC, 18 V charger
52049189
18 V, 3 Ah lithium-ion battery
52054992
Li (18 V) to NiCd, NiMH (12 V) charger adapter
52049201
120 VAC, 18 V charger
50122746
Carrying strap
Greenlee / A Textron Company
5
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
Operation
• Inspect tool and dies before use. Replace any
worn or ­damaged parts. A damaged or improperly ­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 environments; 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.
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.
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 incorporating several important features to inform the user
about the current status of the unit. The LED signals in
the following cases:
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
flying debris or hydraulic oil.
What happens
Pinch points:
• Remove battery before changing
dies, adapters, or jaws.
• Keep hands away from the crimping tool head when crimping.
Failure to observe these warnings
could result in severe injury or death.
Greenlee / A Textron Company
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.
6
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
Operation (cont’d)
Preparation
Follow the lug manufacturer’s instructions for appropriate cable strip length.
Crimping Procedure
1. Insert cable fully into connector. Center the connector between the nibs.
CRIMPING DIRECTION
RIGHT
1ST COMPRESSION
1ST COMPRESSION
SIDE A
CRIMPING DIRECTION
SIDE B
Small connectors may become
wedged between the nibs of
the tool. Center the connector
between the four nibs before
crimping.
Failure to observe this precaution
may cause property damage.
WRONG
2. Pull the trigger to advance the nibs. Hold the trigger
down until the pressure relief valve activates.
Note: Pressure relief occurs at approximately
690 bar (10,000 psi) and is indicated by an audible
“pop.”
3. After achieving pressure relief, the ram automatically
returns to the start position and the nibs retract.
4 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.
5. Complete the number of crimps specified by the
connector manufacturer.
1ST COMPRESSION
SIDE B
CRIMPING DIRECTION
SIDE A
An incomplete crimp can cause a fire.
• 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
7
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
Connector Selection
Tool Range: Copper — 4 AWG to 750 kcmil (except as noted ∆)
Aluminum — 6 AWG to 750 kcmil (except as noted q)
This tool is cUL and UL classified for use with the following connector brands:
CONNECTOR BARREL
ANDERSON BLACKBURN®
TYPE
TYPE
Copper
Splices
Copper
Lugs
Dual-rated
Aluminum
Splices
Dual-rated
Aluminum
Lugs
BURNDY
ILSCO
PANDUIT
T&B
PENNUNION
Short
VHSS
CSP∆
YS-L∆
CT∆
SCSS/SCS∆
54507–54523TB∆
BCU
Long
VHS
CU∆
YS∆
CTL∆
SCL/SCH∆
54807–54823∆
BBCU
Short
VHCS
CTL-2/CTL∆
YA-2LN/YA-L/YA-2L∆
YA/YA-L-TC/YA-L-2TC
CSW∆
CRA/CRB
LCAS/LCA∆
LCD
54107–54123TB∆
54207–54223
BLU
Long
VHCL
CTL-L/LCN∆
YA-2N∆
CLN, CLW∆
CRA-L/CRB-L
CRA-2L/CRB-2L
LCB/LCC∆
54933BE–54923BE∆
54855BE–54880BE
BBLU
—
VACS
ASPq
YS-Aq
AS
SAq
60507–50578
PIKq
VACL
ATLq
YA-Aq
YA-ATN
ACL/ACN
2ACL/2ACN
LAAq
LAB
60106–60178
60230–60278
BLUAq
NO. OF
CRIMPS*
A
B
—
*Use the number of crimps listed in the last column instead of
the number provided with the connector:
A —4 to 4/0 AWG:1 crimp
B ­—
6 to 1 AWG:1 crimp
250 to 600 kcmil:2 crimps
1/0 AWG to 350 kcmil:2 crimps
750 kcmil:3 crimps
400 to 600 kcmil:3 crimps
750 kcmil:4 crimps
Greenlee / A Textron Company
8
∆ 2 AWG to 750 kcmil
qBlackburn: 4 AWG to 750 kcmil
Burndy:
4 AWG to 750 kcmil
Panduit:
4 AWG to 500 kcmil
Penn-Union: 6 AWG to 500 kcmil
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
Maintenance
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.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
flying 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, gangrene, or death.
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.
Do not use solvents or flammable
liquids to clean the tool body.
Solvents or flammable liquids could
ignite and cause serious injury or
property damage.
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.
Pinch points:
• Remove battery before changing
dies, adapters, or jaws.
• Keep hands away from the crimping 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.
Greenlee / A Textron Company
9
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL 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.
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.
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.
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.
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.
Motor is inoperative.
Motor runs but tool will not
complete a cycle.
Dies stop during operation.
Note: For Warranty Service or Repair, contact Greenlee customer service at 800-435-0786.
Greenlee / A Textron Company
10
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK06FTL Battery-powered Crimping Tool
Greenlee / A Textron Company
11
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com
USA Tel: 800-435-0786
Fax: 800-451-2632
Canada Tel: 800-435-0786
Fax: 800-524-2853
International Tel: +1-815-397-7070
Fax: +1-815-397-9247