Greenlee GATOR EK06AT Manual de usuario

GATOR™

EK06AT and EK06ATC

BATTERY-POWERED

CRIMPING TOOLS

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

Table of Contents

Description

The EK06AT and EK06ATC Battery-Powered Crimping

Tools are hand-held, self-contained dieless crimping

tools intended to crimp aluminum and copper connec-

tors onto electrical cable.

The EK06ATC has a rubber coated head.

Purpose

This instruction manual is intended to familiarize opera-

tors and maintenance personnel with the safe operation,

troubleshooting and repair procedures for the Greenlee

EK06AT and EK06ATC.

Keep this manual available to all personnel.

Replacement manuals are available upon request

at no charge.

and are registered trademarks

of Greenlee Textron.

Safety

Safety is essential in the use and maintenance of

Greenlee tools and equipment. This instruction manual

and any decals 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.

KEEPTHIS MANUAL

Description .....................................................................2

Purpose..........................................................................2

Important Safety Information ......................................3-4

Identification...................................................................5

Location of Decals .........................................................6

Specifications.................................................................6

Operation ....................................................................7-8

Periodic Pressure Relief Valve Check...........................9

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

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

Service

Disassembly ..........................................................11

Assembly ...............................................................12

Exploded Views ......................................................13-15

Parts List .................................................................16-18

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

IMPORTANT SAFETY INFORMATION

Electric shock hazard:

This tool is not insulated. When

using this unit near energized

electrical lines use proper personal

protective equipment.

Failure to observe this warning can

result in severe injury or death.

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.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Hazards which, if not avoided, COULD result in severe

injury or death.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

SAFETY

ALERT

SYMBOL

Skin injection hazard:

Oil under pressure easily punctures

skin causing serious injury, gangrene

or death. If you are injured by

escaping oil, seek medical attention

immediately.

• Do not use hands to check for

leaks.

• Depressurize the hydraulic system

before servicing.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris or hydraulic oil.

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Failure to observe this warning can

result in severe injury or death.

Do not use solvents or flammable

liquids to clean the crimping tool.

Solvents or flammable liquids could

ignite and cause serious injury or

property damage.

An incomplete crimp can cause a fire.

• Use proper connector and cable combinations.

Improper combinations can result in an incom-

plete crimp.

• The relief valve will sound to indicate a completed

crimp. If you do not hear the sound of the relief

valve, the crimp is not complete.

Failure to observe these warnings can result in

severe injury or death.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

IMPORTANT SAFETY INFORMATION

Do not dispose of batteries in a fire. Batteries will

vent harmful vapors and may explode.

Failure to observe this warning can result in

severe injury or death.

Inspect tool before use. Replace any worn or dam-

aged

parts. A damaged or improperly assembled

tool can break and strike nearby personnel.

Failure to observe this warning can result in severe

injury or death.

• Do not store the battery at more than 60°C

(140°F). Damage to the battery can result.

• Do not attempt to open the battery. It contains

no user-serviceable parts.

• Do not charge the battery with another type of

charger. Other chargers may overcharge and

damage the battery.

Failure to observe these precautions can result in

injury or property damage.

Note: Keep decals clean and legible. Replace decals

when necessary.

• Keep hands away from the

crimping tool head when crimping.

• Lock trigger when not in use.

Failure to observe these warnings

can result in severe injury or death.

• Do not operate the tool without a connector in

place. Damage to the ram or crimping tool head

can result.

• This tool is not designed for continuous use.

After 30-40 crimping cycles, allow the crimping

tool to cool for 15 minutes.

• Do not place the tool in a vise. The crimping tool

is designed for hand-held operation.

• Protect the crimping tool from rain and moisture.

Water will damage the crimping tool and battery.

• Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions can result in

injury or property damage.

Do not allow any object to contact the battery

terminals.

• Do not immerse 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 can result in

injury or property damage.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

Identification

EK06AT

1. Trigger 5. Crimping Head

2. Trigger Lock 6. Housing

3. Battery 7. Battery Load Display

4. Retract Button 8. Hand Guard

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

Crimping Tool

Length.........................................................................................355 mm (14")

Width ..........................................................................................355 mm (14")

Height .............................................................................................76 mm (3")

Mass/Weight (with battery)..............................................5.03 kg (11 lbs 1 oz)

Sound Level .................................................................... 75 dB (A) at 1 Meter

Vibration .................................................................................(< or >) 2.5 m/s2

Motor Type ..........................................Direct-Current Permanent Field Motor

Motor Voltage ...................................................................................... 12 VDC

Hydraulic Oil ........................................................ ml (pint) of Shell Tellus T15

Crimping Capacities

Cable Size (Aluminum or Copper) ................................. (#8 AWG - 500 MCM)

Crimping Force.......................................................................55 kN (6.2 tons)

Crimping Time ................................................................................ 7 Seconds

Crimps per Charge ...................................................Approximately 40/charge

Battery

Charging Voltage...................................................................................... 12 V

Charging Time.......................................................................................1 Hour

Specifications

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

Operation

Charging the Battery

Read the instructions supplied with the battery charger.

Battery Condition

Preparation

Follow the lug manufacturer’s instructions for appropriate

cable strip length.

Battery Load Display Battery Condition

Momentary illumination Normal

at beginning of crimp

Flickering at end of crimp Normal

Flickering during entire crimp Low charge

Constant illumination Low charge

during entire crimp

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

SIDE B

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

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 can result in severe

injury or death.

• Keep hands away from the

crimping tool head when crimping.

• Lock trigger when not in use.

Failure to observe these warnings

can result in severe injury or death.

1. Insert cable fully into connector. Center the connec-

tor between the nibs.

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 will auto-

matically return to the start position and the nibs

will retract.

4. Complete the number of crimps specified by the

connector manufacturer.

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

can cause property damage.

Operation (cont’d)

Electric shock hazard:

The EK06AT is not insulated. When

using this unit near energized

electrical lines use proper personal

protective equipment.

Failure to observe this warning can

result in severe injury or death.

An incomplete crimp can cause a fire.

The relief valve will sound to indicate a completed

crimp. If you do not hear the sound of the relief

valve, the crimp is not complete.

Failure to observe this warning can result in severe

injury or death.

Crimping

Wear eye protection when operating

this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris or hydraulic oil.

RIGHT

WRONG

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

Maintenance

Do not use solvents or flammable

liquids to clean the crimping tool.

Solvents or flammable liquids could

ignite and cause serious injury or

property damage.

Periodic Pressure Relief Valve Check

Test the crimping tool periodically to ensure that the

pressure relief valve activates at the proper pressure.

Testing the Crimping Tool

1. Center a test slug between the nibs.

2. Pull the trigger to advance the nibs. Hold the trigger

down until the pressure relief valve activates.

3. After achieving pressure relief, the ram will auto-

matically return to the start position and the nibs will

retract.

4. Evaluate the test slug as follows:

• If the test slug does not fit into GO slot, the

pressure relief valve is set too high. Send the

crimping tool to an authorized Greenlee service

center.

• If the test slug fits into the GO slot, the pressure

relief valve is set correctly.

• If the test slug fits into the NO GO slot, the

pressure relief valve is set too low. Send the

crimping tool to an authorized Greenlee service

center.

1. Inspect nibs for wear or damage such as cracks,

gouges or chips.

2. Inspect the crimping tool for damage or leaks. Have

a damaged or leaking crimping tool repaired at an

authorized Greenlee service center.

After Each Use

1. Wipe all tool surfaces clean with a damp cloth and

mild detergent.

2. Fully retract and lock the trigger. Place the crimping

tool in the carrying case. Store in a cool, dry place.

3. Charge the battery.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

Annually or Every 10,000 Crimps

1. Change the hydraulic oil.

2. Return the tool to an authorized Greenlee service

center for inspection.

Checking the Oil Level

1. Remove the two screws (215) that retain the tank

housing cover.

2. Remove the tank housing cover (214).

3. Point the crimping head downward and remove the

oil plug (16). Add oil if necessary.

4. Replace the oil plug and the tank housing cover.

Secure with screws.

Recommended Hydraulic Oils

AVIA HVI 15

Shell Tellus T-15

Mobil DTE 11

NUTO H 15

NO GO

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070

EK06AT and EK06ATC

Troubleshooting

Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.

of tool.

Crimping tool battery contacts damaged.

Reform contacts.

Tool components worn or damaged. Return tool to an authorized

Greenlee service center.

Ram does not advance com- Oil level is low. Check oil level. Refill reservoir.

pletely. Air in hydraulic system. Pull trigger and hold retract button

simultaneously. Hold for approximately

10 seconds.

Battery load display flashes Battery charge low. Charge or replace battery.

constantly.

Tool loses oil. Damaged internal seal. Return tool to an authorized Greenlee

service center.

Oil plug not installed properly. Refill reservoir and replace plug.

PROBLEM PROBABLE CAUSE PROBABLE REMEDY

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 crimping tool.

3. Reinstall battery and check the tool again.

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