Greenlee GATOR EK425 Manuel utilisateur

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

GATOR®EK425

Battery-powered

Crimping Tool

Serialnummer

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

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 Greenlee Textron Inc.

Tellus is a registered trademark of Shell Oil Company.

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

Die and Connector Selection ......................................... 8

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

Troubleshooting.............................................................. 9

Illustrations ............................................................. 10–13

Parts List ...................................................................... 14

Description

The EK425 Battery-powered Crimping Tool is a

hand-held, self-contained crimping tool with removable

crimping jaws.

Safety

Safety is essential in the use and maintenance of Fair-

mont tools and equipment. This manual and any mark-

ings 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 Fairmont tool:

EK425 Battery-powered Crimping Tool

Keep this manual available to all personnel.

Replacement manuals are available upon request

at no charge.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

IMPORTANT SAFETY INFORMATION

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 infor-

mation 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

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.

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.

Do not use solvents or ammable

liquids to clean the crimping tool.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

An incomplete crimp can cause a re.

• Use proper die, connector, and cable combina-

tions. Improper combinations can result in an

incomplete crimp.

• The relief valve will sound to indicate a com-

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

relief valve, 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 near energized

electrical lines, use proper personal

protective equipment.

Failure to observe this warning could

result in severe injury or death.

Skin injection hazard:

Do not use hands to check for

oil leaks. High pressure oil easily

punctures skin causing serious

injury, gangrene, or death. If injured,

seek medical help immediately to

remove oil.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

IMPORTANT SAFETY INFORMATION

• This tool is not designed for continuous use.

After 30 to 40 crimping cycles, allow the crimp-

ing tool to cool for 15 minutes.

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

is designed for hand-held operation.

• This tool may be used in damp or wet environ-

ments; however, we recommend air-drying the

tool before use if it becomes soaked.

• Use this tool for the manufacturer’s intended

purpose only.

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.

Failure to observe this warning 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.

Keep hands away from the crimping

head when crimping.

Failure to observe this warning 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 store the battery at more than 60 °C

(140 °F). 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.

Note: Keep all decals clean and legible, and replace

when necessary.

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.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

IdenticationIdentication

Speciﬁcations

1. Lock Pin

2. Crimping Jaws

3. Jaw Covers

4. Retract Button

5. Battery Lock

6. Battery Cartridge

7. Trigger

Crimping Tool

Length ...............................................................................................................465 mm (18-1/4")

Width.....................................................................................................................60 mm (2-3/8")

Depth ....................................................................................................................98 mm (3-7/8")

Mass/Weight (with battery)...................................................................................... 2.5 kg (5.5 lb)

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

Vibration ........................................................................................................................< 2.5 m/s2

Hydraulic Oil...................................................................................................... Shell Tellus®T 15

Recommended Operating Temperature Range ................... -15 °C (5 °F) through 50 °C (120 °F)

Crimping Capacities

Maximum Crimping Force.......................................................................................44 kN (5 tons)

Average Crimping Time................................................................................................ 4 seconds

Average Crimps per Charge.............................................................................. approximately 85

Battery

Charging Voltage...................................................................................................................9.6 V

Charging Time.................................................................................................................... 45 min

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

Operation

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.

• This tool is not designed for continuous use.

After 30 to 40 crimping cycles, allow the crimp-

ing tool to cool for 15 minutes.

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

is designed for hand-held operation.

• This tool may be used in damp or wet environ-

ments; however, we recommend air-drying the

tool before use if it becomes 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 near energized

electrical lines, use proper personal

protective equipment.

Failure to observe this warning could

result in severe injury or death.

Keep hands away from the crimping

head when crimping.

Failure to observe this warning could

result in severe injury or death.

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

Operation (cont’d)

Charging the Battery

Read the instructions supplied with the battery charger.

Die Selection

Interchangeable dies may be used in the standard die

opening. Dies that may be used include:

• Greenlee KD6 series

• Burndy W and X series

• ILSCO ND series

• Huskie HT58 series

• Panduit CD-2001 series

• Other industry W-type dies

Installing Dies

1. Select the proper dies for the connector to be

crimped.

2. Install dies in jaws making certain that they are

properly secured by the spring-loaded, positive

lock, die buttons.

Preparing Cable

Follow the lug manufacturer’s instructions for appro-

priate cable strip length.

Crimping Procedure

1. Insert conductor into the connector and align the

tool and die on the connector. Start in the center for

splices and “H” frames; and on the end, nearest the

pad, for terminals.

2. Activate the tool by pulling the trigger. Continue to

hold the trigger until the ram retracts. This is the

signal that the crimp is complete.

3. Continue crimping the connector until the correct

number of crimps has been completed. Work from

the center to the outer edges for splices and “H”

frame connectors, alternating sides if possible, for

the best compression connections.

Crimping Direction

First Compression

Crimping Direction

SIDE A

Crimping Direction

SIDE B

First Compression

SIDE A

First Compression

SIDE B

An incomplete crimp can cause a re.

• Use proper die, connector, and cable combina-

tions. Improper combinations can result in an

incomplete crimp.

• The relief valve will sound to indicate a com-

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

relief valve, the crimp is not complete.

Failure to observe these warnings could result in

severe injury or death.

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

CJ22 Jaw and KA22/KC22-type Die Selection

Note: This tool will provide a cUL and UL classiﬁed crimp ONLY when used with the CJ22 jaws and KA22- or KC22-type dies.

Crimps made on copper cable with Greenlee KC22-type dies and the copper connectors listed here are

cUL and UL classied.

Crimps made on copper or aluminum cable with Greenlee KA22-type dies and the dual-rated aluminum connectors

listed here are cUL and UL classied.

Refer to “Connector Selection” for brand names and model numbers of appropriate lugs as well as crimping instructions.

Connector Selection

CJ22 Crimping Jaw 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 classied for use with the following connector brands:

Dies for Copper Connectors Dies for Dual-rated Aluminum Connectors

When used with KA22-type dies, this tool is cUL and UL classied for use with the following connector brands:

* Use the number of crimps listed in the last column instead of the number provided with the connector:

B — 8 to 2 AWG: 2 crimps

1 to 3/0 AWG: 3 crimps

4/0 AWG to 350 kcmil: 4 crimps

A — 8 to 1/0 AWG: 1 crimp

2/0 AWG to 600 kcmil: 2 crimps

** 6 AWG to 350 kcmil

†500 kcmil maximum with Penn-Union connectors

Connector Barrel Anderson Blackburn®FCI Burndy Ilsco Panduit T&B Penn- No. of

Type Type Union† Crimps*

Copper Short VHSS CSP YS-L CT SCSS/SCS 54504–54518 BCU

Splice Long VHS CU YS CTL SCL/SCH 54804–54818 BBCU

Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54104–54118 BLU A

Copper YA/YA-L-TC/YA-L-2TC LCD 54204–54218

Lugs Long VHCL CTL-L/LCN YA-2N CRA-L/CRB-L LCB/LCC 54930BE–54918BE BBLU

CRA-2L/CRB-2L 54850BE–54876BE

Connector Barrel Anderson Blackburn®FCI Burndy Ilsco Panduit T&B Penn- No. of

Type Type Union Crimps*

Dual-rated

Aluminum — VACS ASP YS-A AS SA 60501–60565 PIK

Splice ** B

Dual-rated YA-A ACL/ACN LAA/LAB 60101–60166

Aluminum — VACL ATL BLUA

Lugs YA-ATN 2ACL/2ACN ** 60230–60267

95R7

Catalog UPC Cable Color

Number Number Size Code

KC22-8 03079 8 AWG Red

KC22-6 03080 6 AWG Blue

KC22-4 03081 4 AWG Gray

KC22-2 03082 2 AWG Brown

KC22-1 03083 1 AWG Green

KC22-1/0 03084 1/0 AWG Pink

KC22-2/0 03085 2/0 AWG Black

KC22-3/0 03086 3/0 AWG Orange

KC22-4/0 03087 4/0 AWG Purple

KC22-250 03088 250 AWG Yellow

KC22-300 03089 300 AWG White

KC22-350 03090 350 AWG Red

KC22-400 03091 400 AWG Blue

KC22-500 03092 500 kcmil Brown

KC22-600B 08094 600 kcmil Green

Catalog UPC Cable

Number Number Size

KA22-8 06744 8 AWG

KA22-6 06745 6 AWG

KA22-4 06746 4 AWG

KA22-2 06747 2 AWG

KA22-1 06749 1 AWG

KA22-1/0 06750 1/0 AWG

KA22-2/0 06751 2/0 AWG

KA22-3/0 06752 3/0 AWG

KA22-4/0 06753 4/0 AWG

KA22-250 06754 250 AWG

KA22-300 06755 300 AWG

KA22-350 06756 350 AWG

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

Maintenance

Each Operating Day

Before use:

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

gouges, or chips.

2. Inspect the tool for damage or leaks. If damage is

detected, return the tool to an authorized Fairmont

service center for inspection.

Skin injection hazard:

Do not use hands to check for oil

leaks. High pressure oil easily punc-

tures skin causing serious injury,

gangrene, or death. If injured, seek

medical help immediately to remove

oil.

After use:

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

mild detergent.

Troubleshooting

Before You Begin

1. Make sure that the battery is charged. Recheck the

battery after several minutes to make sure the bat-

tery is holding its charge.

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

of tool.

Crimping tool battery contacts Reform contacts.

damaged.

Tool components worn or damaged. Return tool to an authorized

Fairmont service center.

Dies stop during operation. Oil level is low. Return tool to an authorized

Fairmont service center.

Air in hydraulic system. Pull trigger and hold retract button

simultaneously. Hold for approximately

10 seconds.

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

Fairmont service center.

2. Use a nonﬂammable contact cleaner or pencil

eraser to clean the electrical contacts on the battery

and crimping tool.

3. Reinstall the battery and check the tool again.

 Problem ProbableCause ProbableRemedy

2. Fully retract the ram. Place the tool in the carrying

case. Store in a cool, dry place.

3. Charge the battery.

Monthly

1. Thoroughly clean all surfaces.

2. Oil the pin joints.

Annually or After 10,000 Crimps

Return the tool to an authorized Fairmont service center

for inspection.

Do not use solvents or ammable

liquids to clean the crimping tool.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

EK425 Battery-powered Crimping Tool

Illustrations

Main

7 6

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