GATOR® EK12IDL Battery-powered, Dieless Crimping Tool

GATOR® EK12IDL Battery-powered, Dieless Crimping Tool
OPERATION MANUAL
GATOR EK12IDL
Battery-powered,
Dieless Crimping Tool
В®
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
52047656 REV 4
В© 2011 Greenlee Textron Inc.
7/11
EK12IDL Battery-powered, Dieless 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 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 В­provided.
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 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 Greenlee Textron 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
EK12IDL Battery-powered, Dieless 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
В­servicing 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
EK12IDL Battery-powered, Dieless Crimping Tool
IMPORTANT SAFETY INFORMATION
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.
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 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 d
В­ amaged parts. A damaged or improperly В­assembled 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 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
EK12IDL Battery-powered, Dieless Crimping Tool
Identification
5
  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
4
6
3
8
2
7
1
10
9
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 fluid
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
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
EK12IDL Battery-powered, Dieless Crimping Tool
Operation
Inspect tool and dies before use. Replace any
worn or d
В­ amaged parts. A damaged or improperly В­assembled 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 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.
Signal
What it means
Flashing light for 2В seconds
Battery is inserted in tool
Constant light for 20В seconds
at end of cycle
Battery charge is below
17В V at beginning of cycle
Tool will not start, and
constant light for 20В seconds
when trigger is released
Battery charge is below
16В V at beginning of cycle
Tool will stop, and constant
light for 20В seconds after
trigger is released
Battery voltage drops
below 13В V during cycle
Tool will stop, and flashing
light for 20В seconds when
trigger is released
Motor current exceeds
20В 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.
Greenlee / A Textron Company
6
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK12IDL Battery-powered, Dieless Crimping Tool
Operation (cont’d)
Preparation
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.
For a cUL or UL classified 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.
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.
Connector
3. If open, close the crimping head. Make sure the
head and latch are fully engaged.
4. For a cUL or UL classified crimp, complete the
number of crimps specified 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 connector marks.
Greenlee / A Textron Company
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.
7
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK12IDL Battery-powered, Dieless Crimping Tool
cUL and UL Classified Crimps
Crimps made with the Greenlee EK12IDL Dieless
Crimping Tool are cUL and UL classified 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
Copper Splices
Copper Lugs
*Number of
Crimps
Copper Cable Size:
4 AWG–1000 kcmil
Aluminum Connector Type
Anderson BlackburnВ®
VHSS
VHS
CSP
CU
VHCS
VHCL
CTL
CTL-L
LCN
1
1
Anderson BlackburnВ®
Burndy
Ilsco
Panduit
T&B
YS-L
YS
CT
CTL
SCSS
54506 to 54528
SCS
54806 to 54828
SCL, SCH
CLN, CLW, CSW
54106 to 54128
YA, YA-L, YA-2L
LCAS
CRA, CRB, CRC
54206 to 54228
YA-2LN, YA-2N
LCA
CRA-L, CRB-L
54906BE to
YA-L-TC, YA-L-2TC
LCB
CRA-2L
54928BE
YA-2TC, YAZ
LCD, LCC
CRB-2L
54854BE to
YAZ-2N, YAZ-2TC
LCAN
CRC-2L
54882BE
PennUnion
Tyco (AMP)
BCU
BBCU
—
BLU
BBLU
1099898-2 to
1-1099898-5
1099899-2 to
1-1099899-9
1099939-1 to
1-1099939-5
1
1
1
1
1
1
Burndy
Ilsco
Panduit
T&B
PennUnion
Dual-Rated Aluminum Splices
VACS
ASP
YS-A
AS
SA
60507 to 60584
PIK
BCUA
Dual-Rated Aluminum Lugs
VACL
ATL
YA-A
YA-A-TN
ACL, ACN
2ACL, 2ACN
LAA
LAB
60106 to 60184
60230 to 60284
BLUA
Cable Size:  6 AWG–500 kcmil
*Number of
Cable Size:  600 kcmil–800 kcmil
Crimps
Cable Size:  1000 kcmil
1
1
1
1
1
1
1
2
1
1
1
2
1
1
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.
Greenlee / A Textron Company
8
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK12IDL Battery-powered, Dieless 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 360В°. If damage is detected, send the tool to a
Greenlee В­Authorized 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 В­Authorized 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.
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
EK12IDL Battery-powered, Dieless 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
ofВ tool.
Clean tool.
Tool battery contacts damaged.
Reform contacts.
Tool components worn or damaged.
Return tool to a Greenlee В­Authorized
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 В­Authorized
Service Center.
Oil level low.
Return tool to a Greenlee В­Authorized
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 В­Authorized 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 В­Authorized
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 В­Authorized
Service Center.
Motor is inoperative.
Motor runs but tool will not
complete a cycle.
Dies stop during operation.
Greenlee / A Textron Company
10
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK12IDL Battery-powered, Dieless 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
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