GATOR® EK622PLU Battery

OPERATION MANUAL
Serial Number
GATOR EK622PLU
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
52066131 REV 2
© 2016 Greenlee Textron Inc.
7/16
EK622PLU 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
Die and Connector Selection.......................................... 8
Maintenance.................................................................... 9
Troubleshooting............................................................. 10
The EK622PLU Battery-powered, High-speed Crimping
Tool is a hand-held, self-contained crimping tool
­intended to crimp copper and aluminum cable with
KC22-type, KA22-type, and W-type dies.
This tool is protected by U.S. Patent No. 6,206,663,
6,267,186, 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 Utility tool:
EK622PLU 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
EK622PLU 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
EK622PLU Battery-powered 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.
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.
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.
• 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
EK622PLU Battery-powered Crimping Tool
Identification
10
1. W-type Die Detents
2. Die Release Buttons
3. Locking Flange
4.Trigger
5.Battery
6. LED Work Light (white)
7. LED Indictor (red)
8. Retract Button
9.Housing
10. Lanyard Ring
1
9
7
8
6
2
3
4
5
Specifications
Crimping Tool
Length.............................................................................................14.3" (363.6 mm)
Width.................................................................................................2.87" (72.9 mm)
Height (with battery)........................................................................10.9" (278.5 mm)
Weight.................................................................................................9.26 lb (4.2 kg)
Crimping Force..................................................................................... 6 tons (53 kN)
Hydraulic Oil................................................52057878 biodegradable hydraulic fluid
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
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
EK622PLU 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
EK622PLU Battery-powered Crimping Tool
Operation (cont’d)
Installing K22, KA22, and KC22-type Dies
1. Select the proper dies for the intended crimp.
2. Push the die release button.
3. Slide the die into the crimping head until it “snaps”
into place.
4. Properly position the second die. Repeat steps 2
and 3.
Crimping Cable
1. Press the locking flange and open the crimping
head.
2. Insert the properly assembled connector into the
crimping head.
3. Close the crimping head.
4. Pull the trigger to make the crimp.
5. Hold the trigger down until the crimping tool
achieves pressure relief and the ram retracts.
6. The crimping tool returns automatically.
7. Position the crimping tool for next crimp. Repeat
Steps 4 through 6 for the number of crimps as
described in this manual.
8. Open the crimping head and remove the connector.
Notes: If it is necessary to retract the ram before a
crimping cycle is completed, push the retract button.
Pushing the retract button will result in the complete
retraction of the ram.
After completing the last crimp with W-type dies on an
aluminum connector, wipe off the excess oxide inhibitor.
Installing W-type Dies
1. Push the die release button.
2. Slide the die adapter (Greenlee part number
50042920) into crimping head until it “snaps” into
place.
Note: The die adapters have the “D3” die profile. No
additional dies are needed if the connector to be
crimped requires a “D3” die.
3. Repeat for the other adapter.
4. Select the proper dies for the intended crimp.
5. Press the locking flange and open the crimping
head.
6. Push the W-type die detent and slide the W-type die
into place.
7. Properly position the second die. Repeat steps 5
and 6.
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.
Preparing Cable
Follow the lug manufacturer’s instructions for appropriate cable strip length.
Crimping Direction
First Compression
First Compression
SIDE A
Crimping Direction
SIDE B
First Compression
SIDE B
Crimping Direction
SIDE A
Greenlee / A Textron Company
7
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK622PLU Battery-powered Crimping Tool
Die Selection
Crimps made on copper cable with Greenlee KC22-type dies and the copper connectors listed here are
cUL and UL classified.
Crimps made on copper or aluminum cable with Greenlee KA22-type dies and the dual-rated aluminum connectors
listed here are cUL and UL classified.
Refer to “Connector Selection” for brand names and model numbers of appropriate lugs as well as crimping
instructions.
W-type or X-type dies can be used to crimp 8 AWG to 500 kcmil copper and 8 AWG to 4/0 AWG aluminum.
Dies for Copper Connectors
Catalog Number
KC22-8
KC22-6
KC22-4
KC22-2
KC22-1
KC22-1/0
KC22-2/0
KC22-3/0
KC22-4/0
KC22-250
KC22-300
KC22-350
KC22-400
KC22-500
KC22-600
UPC Number
03079
03080
03081
03082
03083
03084
03085
03086
03087
03088
03089
03090
03091
03092
03093
Dies for Dual-rated Aluminum Connectors
Cable Size
8 AWG
6 AWG
4 AWG
2 AWG
1 AWG
1/0 AWG
2/0 AWG
3/0 AWG
4/0 AWG
250 kcmil
300 kcmil
350 kcmil
400 kcmil
500 kcmil
600 kcmil
Color Code
Red
Blue
Gray
Brown
Green
Pink
Black
Orange
Purple
Yellow
White
Red
Blue
Brown
Green
Catalog Number
UPC Number
Cable Size
KA22-8
KA22-6
KA22-4
KA22-2
KA22-1
KA22-1/0
KA22-2/0
KA22-3/0
KA22-4/0
KA22-250
KA22-300
KA22-350
06744
06745
06746
06747
06749
06750
06751
06752
06753
06754
06755
06756
8 AWG
6 AWG
4 AWG
2 AWG
1 AWG
1/0 AWG
2/0 AWG
3/0 AWG
4/0 AWG
250 kcmil
300 kcmil
350 kcmil
Connector Selection
Tool Range: Copper — 8 AWG to 600 kcmil; Dual-rated Aluminum — 8 AWG to 350 kcmil
When used with KC22-type dies, this tool is cUL and UL classified for use with the following connector brands:
Connector
Type
Barrel
Type
Anderson
Blackburn®
Burndy
Copper
Splice
Short
VHSS
CSP
Long
VHS
CU
Short
VHCS
Long
VHCL
Copper
Lugs
PennUnion
No. of
Crimps*
ILSCO
Panduit
T&B
YS-L
CT
SCSS/SCS
54504-54520
BCU
A
YS
CTL
SCL/SCH
54804-54820
BBCU
B
CTL-2/CTL
YA-2LN/YA-L/YA-2L
YA/YA-L-TC/YA-L-2TC
CSW
CRA/CRB
LCAS/LCA
LCD
54104-54120
54204-54218
BLU
A
CTL-L/LCN
YA-2N
CLN/CLW
CRA-L/CRB-L
CRA-2L/CRB-2L
LCB/LCC
54930BE-54920BE
54850BE-54878BE
BBLU
B
When used with KA22-type dies, this tool is cUL and UL classified for use with the following connector brands:
Connector Type
Barrel Type
Anderson
Blackburn®
Burndy
ILSCO
Panduit
T&B
PennUnion
Dual-rated
Aluminum Splice
—
VACS
ASP
YS-A
AS
ASN
SA**
60501-60565
PIK
Dual-rated
Aluminum Lugs
—
VACL
ATL
YA-A
YA-ATN
ACL/ACN
2ACL/2ACN
ALNS/ALNN/ALND
LAA/LAB**
60101-60166
60230-60267
BLUA
No. of
Crimps*
C
*Use the number of crimps listed in the last column instead of the number provided with the connector:
95R7
A — 8 to 1/0 AWG: 1 crimp
2/0 AWG to 600 kcmil: 2 crimps
**6 AWG to 350 kcmil
Greenlee / A Textron Company
B ­— 8 to 1/0 AWG: 2 crimps
2/0 to 3/0 AWG: 3 crimps
4/0 AWG to 600 kcmil: 4 crimps
8
C ­— 8 to 2 AWG: 2 crimps
1 to 3/0 AWG: 3 crimps
4/0 AWG to 350 kcmil: 4 crimps
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK622PLU 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 Utility 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 Utility 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.
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.
Note: For Warranty Service or Repair, contact Greenlee
customer service at 800-435-0786.
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
EK622PLU 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 components worn or damaged.
Return tool to a Greenlee Utility
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 Utility
Authorized Service Center.
Oil level low.
Return tool to a Greenlee Utility
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 Utility 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 Utility
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 Utility
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
EK622PLU 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