Page 1
INSTRUCTION MANUAL
GATOR® PRO E12CCX
12-ton Battery-powered,
High-speed Tool
with Retraction Stop
Serial Code AKK
Read and understand all of the instructions and
safety information in this manual before operating
of servicing this tool.
Register this product at www.greenlee.com
52031420 REV 1 © 2010 Greenlee Textron Inc. 9/10
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E12CCX 12-ton Battery-powered, High-speed Tool
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information .....................................3–4
Identication .................................................................. 5
Specications ................................................................ 5
Operation ..................................................................6–13
Crimping .................................................................6–7
Cutting ....................................................................... 8
Punching ...............................................................9–13
U-type Crimping Dies for Copper Connectors ............ 14
Connector Selection ................................................ 14
U-type Crimping Dies for Aluminum Connectors ........ 14
Additional U-type Dies ................................................ 15
Available Accessories .................................................. 15
Maintenance ................................................................ 16
Periodic Pressure Relief Valve Check.......................... 16
Troubleshooting ........................................................... 17
Disassembly ................................................................ 18
Assembly ..................................................................... 19
Illustrations .............................................................20–23
Parts List ................................................................24–26
Description
The E12CCX 12-ton Battery-powered, High-speed Tool
is a hand-held, self-contained tool intended to crimp
cable, cut cable and threaded rod, and punch holes with
the proper adapters.
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.
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:
E12CCX 12-ton Battery-powered,
High-speed Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge at www.greenlee.com.
All specications 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 and Kwik Stepper are registered trademarks of Greenlee
Textron Inc.
AVIA is a registered trademark of Avia International.
Blackburn is a registered trademark of Thomas & Betts.
Mobil is a registered trademark of Mobil Oil Corporation.
NUTO is a registered trademark of Exxon Corporation.
Tellus is a registered trademark of Shell Oil Company.
KEEP THIS MANUAL
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
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E12CCX 12-ton Battery-powered, High-speed Tool
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
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, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL 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.
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.
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.
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.
Electric shock hazard:
This tool is not insulated. When using
this unit on or near energized electrical lines, use proper personal protec-
tive equipment.
Failure to observe this warning could
result in severe injury or death.
Do not use solvents or ammable
liquids to clean the tool body.
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 combinations.
Mismatched combinations can result in an incomplete crimp.
• The crimping tool automatically retracts when a
complete crimp has been achieved. If you do not
hear a “pop,” the crimp is incomplete.
Failure to observe this warning could result in severe
injury or death.
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 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 4
E12CCX 12-ton Battery-powered, High-speed Tool
IMPORTANT SAFETY INFORMATION
Do not dispose of the battery in a re. The battery will
vent fumes and it could explode.
Failure to observe this warning could result in severe
injury from harmful fumes or burns from ying debris.
Inspect tool, dies, and adapters 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 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, we recommend air drying the tool
before use if it becomes soaked. Damage may
result when the tool is operated prior to drying out
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.
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.
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 5
Identification
E12CCX 12-ton Battery-powered, High-speed Tool
1. Head
2. Latch (for opening head)
3. Housing
2
4. Retract Button
5. Battery Load Display
1
6. Battery
7. Trigger
8. Adapter Release Buttons
Specifications
Tool
Overall Length .................................. 371 mm (14-5/8")
Width..................................................... 95 mm (3-3/4")
Height ......................................................330 mm (13")
Mass/Weight (with battery) ..................6.5 kg (14.35 lb)
Force ...................................................106 kN (12 tons)
Sound Level ..................................75 dB (A) at 1 meter
Vibration ........................................................ < 2.5 m/s
Motor Type .......................... DC permanent eld motor
Motor Voltage ................................................... 12 VDC
Hydraulic Oil ........ 50 ml (0.1 pint) of Shell Tellus® T 15
Recommended Operating
Temperature Range .............................. –15 °C to 50 °
(5 °F to 120 °F)
Battery
Charging Voltage ..............................................12 VDC
Charging Time .................................................... 1 hour
8
Crimping Capacities
Copper Color-Coded Lugs and Splices ........750 kcmil
Aluminum Color-Coded Lugs and Splices ...750 kcmil
5/8" Service Entrance Connectors...........10–1/0 AWG
.840 Service Entrance Connectors .........1/0–4/0 AWG
Aluminum Overhead “H” Taps .........6 AWG–500 kcmil
One-Piece ACSR
2
Tension Splices ..............................4 AWG–556.5 kcmil
Two-Piece ACSR
Tension Splices ..............................2 AWG–556.5 kcmil
Cutting Capacities
Copper and Aluminum Cable ............... 40 mm (1-1/2")
ACSR .............................................954 kcmil (Cardinal)
Standard Guy Strand..............................................5/8"
EHS Guy Strand .....................................................1/2"
Ground Rod ..............................................13 mm (1/2")
Rebar (schedule 60)..................................13 mm (1/2")
Threaded Rod ......................................1/4", 3/8", 1/2",
4 mm, 5 mm, 6 mm, 8 mm, 10 mm
DIN Rail ...........................35 x 7.5, 32 x 15 x 9, 35 x 15
3
4
5
7
6
Punching Capacities
Round ...............144.1 mm (5-5/8") in 10 ga. mild steel
Rectangular ....68.0 mm x 138.0 mm (2.677" x 5.433")
Square ..........138.0 mm x 138.0 mm (5.433" x 5.433")
Accessories required to punch 4-1/2" through 5-5/8":
12185 spacer, 04686 bushing, and 03170 sleeve
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 6
Operation
E12CCX 12-ton Battery-powered, High-speed Tool
Electric shock hazard:
This tool is not insulated. When using
this unit on or near energized electrical lines, use proper personal protec-
tive equipment.
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.
Crimping
Setup
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Select the appropriate set of die adapters and dies.
4. Install the adapters and dies—one set in each
groove. Lock the die adapters in place with the
detents.
Important: Die adapters must be locked into place
or the die detents will be damaged.
5. Visually check the dies to ensure that they are
aligned correctly so that they will complete the
crimping operation.
6. Close the tool head.
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 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, we recommend air drying the tool
before use if it becomes soaked. Damage may
result when the tool is operated prior to drying out
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.
Die Adapter Detents:
Press and slide the adapter
into place. Release to lock.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 7
Operation (cont’d)
E12CCX 12-ton Battery-powered, High-speed Tool
Crimping (cont’d)
Preparing the Cable
Follow the lug manufacturer’s instructions for appropri-
ate cable strip length.
CRIMPING DIRECTION
1ST COMPRESSION
CRIMPING DIRECTION
SIDE B
1ST COMPRESSION
SIDE A
1ST COMPRESSION
SIDE B
CRIMPING DIRECTION
SIDE A
Crimping Procedure
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.
An incomplete crimp can cause a re.
• Use proper die, connector, and cable combinations.
Mismatched combinations can result in an incomplete crimp.
• The crimping tool automatically retracts when a
complete crimp has been achieved. If you do not
hear a “pop,” the crimp is incomplete.
Failure to observe this warning could result in severe
injury or death.
Battery Condition
The battery indicator illuminates to show battery charge
level as follows:
Normal: Illuminates momentarily at beginning of crimp.
Normal: Flickering at point of maximum crimping force.
Low charge: Flickering during entire crimping cycle.
Low charge: Illuminates continuously when operating
without a load.
1. Press the latch and open the tool head.
2. Insert the properly assembled connector into the
tool head.
3. Close the tool head.
4. Pull the trigger to make the crimp.
5. Hold the trigger down until the crimper achieves
pressure relief.
Notes: Pressure relief occurs at approximately
106 kN bar (12 tons). If you do not hear a “pop,”
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.
6. The ram returns automatically.
7. 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.
8. Position the crimper for the next crimp. Repeat
Steps 4 through 6 for the number of crimps as
described in this manual.
9. Open the crimping head and remove the connector.
Notes: If it is necessary to retract the ram before a
crimp cycle is completed, push the retract button.
Pushing the retract button will result in complete retraction of the ram.
After completing the last crimp on an aluminum
connector, wipe off the excess oxide inhibitor.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 8
Operation (cont’d)
E12CCX 12-ton Battery-powered, High-speed Tool
Cutting
Electric shock hazard:
This tool is not insulated. When using
this unit on or near energized electrical lines, use proper personal protec-
tive equipment.
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.
Setup
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Select the appropriate set of blades, using the
table provided on this page.
4. Install one blade in each groove. Slide the tab into
the slots in the ram and head. Lock them in place
with the W-type detents.
5. Visually check the blades to ensure that they are
aligned correctly so that they will complete the
butting operation.
6. Close the tool head.
Setup for Din Rail Cutters
1. Install both blades in the movable head.
2. Close the head.
3. Slide one blade over until it engages in the W-type
detent in the ram slot. Slide the other blade over
until it engages in the W-type detent in the head slot.
Accessory Table
Task Blade
Copper and aluminum
26 mm (1.00") max.
Copper and aluminum
40 mm (1.56") max.
ACSR
Copperweld
ACAR
Guy strand
EHS guy strand
Ground rod
Anchor rod
Soft bolts
Rebar
Threaded rod Threaded rod
DIN rail DIN rail
UC26
UC40
UCACSR
Detents:
Press and slide the
adapter and/or die
into place.
Release to lock.
Cutting Procedure
1. Press the latch and open the tool head.
2. Position the item to be cut in the tool head.
3. Close the tool head.
4. Pull the trigger to cut the item.
5. Release the trigger when the cut is complete.
6. The ram returns automatically.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Page 9
Operation (cont’d)
Punching
Electric shock hazard:
Do not use this tool as a punch driver
on or near live circuits. This includes,
but is not limited to, the following
circumstances:
• Energized electrical lines
• Energized circuit breaker panels
and fuse boxes
• Junction boxes with energized
circuits
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.
E12CCX 12-ton Battery-powered, High-speed Tool
A component failure could throw
broken parts.
• Do not allow anyone to stand in
front of the punch.
• Close access doors or covers on
any equipment that is in line with
the punch.
Failure to observe this warning could
result in severe injury or death.
Set up the tool properly. An improper setup could
cause a component to fail and strike nearby
personnel with great force.
• Thread the punch completely onto the draw stud.
All of the punch threads must be engaged by the
draw stud threads. Incomplete assembly could
cause a component failure.
• Use only Greenlee punches, dies, and draw studs.
Other manufacturers’ components might not with-
stand the forces generated by this punch driver.
Failure to observe these warnings could result in
severe injury or death.
Do not attempt to punch a hole
through two or more thicknesses of
material. This will bend or break the
draw stud, and could throw parts with
great force.
Failure to observe this warning could
result in severe injury or death.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Page 10
Operation (cont’d)
E12CCX 12-ton Battery-powered, High-speed Tool
Punching (cont’d)
Setup and Punching Procedure
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Install the punch driver so that the drive piston is
toward the yoke, as shown.
4. Close the tool head.
5. Select the punch, die, and draw stud to make the
appropriate size hole. Refer to the illustrations on
the following pages.
6. Determine and mark the exact location for the hole.
Use a Greenlee Kwik Stepper® drill bit to drill a hole
that is slightly larger than the draw stud. This is the
pilot hole.
7. Push the retract button and hold the button until the
ram is completely retracted.
8. Thread the 3/4" draw stud or 3/4" adapter completely into the punch driver. Refer to the illustrations on the following pages.
Notes: For a punch and die with a 3/8" center hole,
thread the 3/8" draw stud into the end of the 3/4"
adapter.
For 4" and larger punch and die, add the bushing
to the die, slide the spacer over the 3/4" draw stud,
and install the 1-1/8" sleeve.
9. Install a spacer, if necessary. Refer to the illustrations on the following pages.
10. Slide the die over the draw stud with the open end
of the die facing away from the punch driver.
11. Insert the draw stud through the pilot hole.
12. Thread the punch onto the draw stud with the
cutting surfaces of the punch facing the material.
Tighten the punch by hand until the spacer, die,
material, and punch contact each other.
Note: All of the punch threads must be engaged by
the draw stud threads. If any of the punch threads
are not engaged, disassemble the setup, remove the
spacer, and reassemble the setup.
Note: A “popping” sound indicates that the tool
has reached relief pressure. This may indicate that
the attempted operation is beyond the capacity of
the tool.
13. Pull the trigger.
14. Release the trigger when the punch completes the
hole. The ram returns automatically.
15. Unscrew the punch. Remove slugs from the die.
Remove the spacer and unscrew the draw stud.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 11
Operation (cont’d)
Punching (cont’d)
E12CCX 12-ton Battery-powered, High-speed Tool
Round Punches
Metric: 22.5 mm (max.)
Conduit Size: 1/2" (max.)
Actual Size: 0.885" (max.)
Round Punches
Metric: 28.3 mm to 95.2 mm
Conduit Size: 3/4" to 3"
Actual Size: 1.115" to 3.75"
Punch
1/2" (12.7 mm)
Pilot Hole
Die
7/8" (22.2 mm)
Pilot Hole
33967
3/4" Adapter
30043
3/8" Draw Stud
Punch
Driver
03248
Spacer
03248
Spacer
Punch
Driver
2113AA or 29452
3/4" Draw Stud
Round Punches
Metric: 95.2 mm to 143 mm
Conduit Size: 3-1/2" to 5"
Actual Size: 4" to 5-5/8"
1557AA
1-1/8" Sleeve
Punch
Die
29452
3/4" Draw Stud
Punch
Driver
12185 Spacer
3037AV Bushing
Die
Punch
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 12
E12CCX 12-ton Battery-powered, High-speed Tool
Operation (cont’d)
Punching (cont’d)
Square and Rectangular Punches
Metric: 12.7 mm square
Inches: 1/2" square
Metric: 11.1 mm x 22.2 mm rectangular
Inches: 7/16" x 7/8" rectangular
Punch
05244
1/4" Counter Nut
1/4" Draw Stud
Pilot Hole
3/8" Draw Stud
Punch Driver
60114
1/4" Adapter
60115
03248
Spacer
End with Long Threads
Die
Punch Driver
33967
3/8" Adapter
60116
Square and Rectangular Punches
Metric: 15.9 mm to 24.0 mm square
Inches: 5/8" to 0.945" square
Metric: 17.0 mm x 19.0 mm rectangular
Inches: 0.670" x 0.749" rectangular
Square and Rectangular Punches
Metric: 25.4 mm square
Inches: 1" square
Metric: 19.1 mm x 29.0 mm to
31.8 mm x 35.1 mm rectangular
Inches: 0.750" x 1.140" to
1.250" x 1.380" rectangular
Punch
04638
3/8" Counter Nut
Punch
Pilot Hole
3/8" Draw Stud
03248
Spacer
End with Long Threads
Threads with Flats
Die
Punch Driver
60167
1/2" Adapter
60117
03248
Spacer
End with Long Threads
Threads with Flats
Die
Pilot Hole
60258
1/2" Counter Nut
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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Page 13
E12CCX 12-ton Battery-powered, High-speed Tool
Operation (cont’d)
Punching (cont’d)
Square and Rectangular Punches
Metric: 46.0 mm to 68.0 square
Inches: 1.811" to 2.677" square
Metric: 33.3 mm x 66.7 mm to
35.0 mm x 65.0 mm rectangular
Inches: 1.312" x 2.625" to
1.378" x 2.559" rectangular
“D”, Double “D”, and
Key Punches
Punch
3/4" Counter Nut
60235
Pilot Hole
Punch Driver
60118
3/4" Draw Stud
End with Long Threads
Die
Pilot Hole
Punch Driver
Adapter
Draw Stud
03248
Spacer
End with Long Threads
Electronic Connector
Panel Punches
Punch
Counter Nut
04638
3/8" Counter Nut
Die
Punch Driver
Punch
33967
3/8" Adapter
34421
3/8" Draw Stud
03248
Spacer
End with Long Threads
Threads with Flats
Die
7/16" (11.1mm)
Pilot Hole
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
Page 14
E12CCX 12-ton Battery-powered, High-speed Tool
Die Selection
Refer to “Connector Selection” for brand names and model numbers of appropriate lugs as well as crimping instructions.
Crimps made with this tool and KC12-type or KA12-type dies are cUL and UL classied when used with the appropriate conductor
and connectors listed below.
Dies for Copper Connectors
Catalog UPC Cable Color No. of
Number Number Size Code Crimps
KC12-8 10996 8 AWG Red 1
KC12-6 10997 6 AWG Blue 1
KC12-4 10998 4 AWG Gray 1
KC12-2 10999 2 AWG Brown 1
KC12-1 11003 1 AWG Green 1
KC12-1/0 11004 1/0 AWG Pink 1
KC12-2/0 11007 2/0 AWG Black 1
KC12-3/0 11010 3/0 AWG Orange 1
KC12-4/0 11011 4/0 AWG Purple 1
KC12-250 11012 250 kcmil Yellow 1
KC12-300 11013 300 kcmil White 2
KC12-350 11014 350 kcmil Red 2
KC12-400 11015 400 kcmil Blue 2
KC12-500 11016 500 kcmil Brown 2
KC12-600 11018 600 kcmil Green 2
KC12-750 11020 750 kcmil Black 2
Dies for Aluminum Connectors
Catalog UPC Cable Color No. of
Number Number Size Code Crimps
KA12-8 22084 8 AWG Blue 1
KA12-6 22085 6 AWG Gray 1
KA12-4 22086 4 AWG Green 1
KA12-2 22087 2 AWG Pink 1
KA12-1 22088 1 AWG Gold 1
KA12-1/0 22089 1/0 AWG Tan 1
KA12-2/0 22090 2/0 AWG Olive 2
KA12-3/0 22121 3/0 AWG Ruby 2
KA12-4/0 22122 4/0 AWG White 2
KA12-250 22123 250 kcmil Red 2
KA12-300 22124 300 kcmil Blue 2
KA12-350 22125 350 kcmil Brown 2
KA12-400 22126 400 kcmil Green 3
KA12-500 22127 500 kcmil Pink 3
KA12-600 22128 600 kcmil Black 3
KA12-750 22129 750 kcmil Yellow 3
Connector Selection (NOT for use with flex, navy or welding wire)
Tool Range: 8 AWG to 750 kcmil
When used with KC12-type dies, this tool is cUL and UL classied for use with the following connector brands:
Connector
Type
Copper
Splice
Copper
Lugs
Barrel
Type
Short
Long
Short
Long
Anderson
VHSS
VHS
VHCS
VHCL
Blackburn®
CSP
CU
CTL-2/CTL
CTL-L/LCN
FCI
Burndy
YS-L
YS
YA-2LN/
YA-L/YA-2L;
YA/YA-L-TC/
YA-L-2TC
YA/YAZ
YA-2N/YA-2TC
YAZ-2N/YAZ-2TC
Ilsco
CT
CTL
CRA/CRB
CRC
CRA-L/CRB-L
CRA-2/CRB-2L
CRC-2L
Panduit
SCSS
SCS
SCL
SCH
LCAS
LCA
LCD
LCAN
LCB
LCC
T&B
54504 to
54523-TB
54804 to
54823
54104 to
54123-TB;
54204 to
54223
54930BE to
54923BE;
54850BE to
54880BE
PennUnion
BBCU
BBLU
BCU
BLU
Number
of Crimps*
8 AWG to
250 kcmil:
1 crimp
300 to
750 kcmil:
2 crimps
When used with KA12-type dies, this tool is cUL and UL classied for use with the following connector brands:
PIK
Number
of Crimps*
8 to
1/0 AWG:
1 crimp
2/0 AWG to
350 kcmil:
2 crimps
400 to
750 kcmil:
3 crimps
* Use the number of
Connector
Type
Dual-Rated
Aluminum
Splice
Dual-Rated
Aluminum
Lugs
Anderson
VACS
VACL
Blackburn®
ASP
ATL
FCI
Burndy
YS-A
YA-A
YA-ATN
Ilsco
AS
ACL/ACN
2ACL/2ACN
Panduit
SA
LAA
LAB
T&B
60501 to
60578
60101 to
60176;
60230 to
60278
PennUnion
BLUA
crimps listed in this
column instead of the
number provided with
the connector.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
14
Page 15
E12CCX 12-ton Battery-powered, High-speed Tool
Additional U-type Dies
Greenlee Greenlee FCI Burndy
Catalog No. UPC No. No.
KD12-10 10188 U-BG
KD12-11 10189 U-0
KD12-12 10190 U-C
KD12-14 10192 U-161
KD12-15 10193 U-162
KD12-16 10194 U-163
KD12-17 10195 U-165
KD12-18 10196 U-166
KD12-19 10197 U-243
KD12-20 10198 U-247
KD12-21 10199 U-249
KD12-30 10200 U-D3
KD12-31 10201 U-E
KD12-32 10202 U-F
KD12-33 10203 U-997
KD12-35 10205 U-238
KD12-36 10206 U-654
KD12-37 10207 U-655
KD12-38 10208 U-658
KD12-39 10209 U-659
KD12-40 10210 U-998
Available Accessories
Adapter Greenlee Description
Part No.
UC26 50067141 Cutter blades for copper and
aluminum 26 mm (1") max.
UC40 50070363 Cutter blades for copper and
aluminum 40 mm (1-1/2") max.
UCACSR 50070371 Cutter blades for ACSR, ACAR,
standard guy wire, EHS guy wire,
copperweld, ground rod, anchor rod,
soft bolts, rebar
UCUNC14 50070380 Cutter blades for 1/4" threaded rod
UCUNC38 50070398 Cutter blades for 3/8" threaded rod
UCUNC12 50072749 Cutter blades for 1/2" threaded rod
UCM5 50070533 Cutter blades for M5 threaded rod
UCM6 50070509 Cutter blades for M6 threaded rod
UCM8 50070517 Cutter blades for M8 threaded rod
UCM10 50070525 Cutter blades for M10 threaded rod
UCD3575 50070410 DIN rail cutter blades—35 x 7.5
UCD3215 50070428 DIN rail cutter blades—32 x 15
UCD3515 50070436 DIN rail cutter blades—35 x 15
UA12P 50118900 Punch driver adapter
04686 50046861 Die bushing*
12185 50121855 Spacer*
03170 50031708 Punch sleeve, 1-1/8"*
*
Required for knockout punches larger than 4" actual diameter.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
15
Page 16
Maintenance
E12CCX 12-ton Battery-powered, High-speed Tool
Each Operating Day
Before use:
1. Inspect dies and adapters 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 Greenlee
service center for inspection.
High pressure hazard:
Do not use ngers or hands to check
for oil leaks. High pressure oil easily
punctures skin causing serious injury,
gangrene, or death.
If injured, seek medical help immedi-
ately to remove oil.
After use:
1. Wipe all tool surfaces clean with a damp cloth and
mild detergent.
Do not use solvents or ammable
cleaners to clean the tool body.
Solvents could ignite, causing serious
injury or property damage.
2. Place 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.
3. Oil the bolt joints.
Annually or After 10,000 Cycles
1. Change the hydraulic oil.
2. Return the tool to an authorized Greenlee service
center for inspection.
Recommended Hydraulic Oils
AVIA
Shell Tellus T 15
Mobil® DTE 11M
NUTO® H 15
®
HVI 15
Periodic Pressure Relief Valve Check
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.
The crimping tool’s relief valve may require occasional
adjustment. To determine whether this adjustment is
necessary, periodically test the crimping tool with a
Greenlee model 35887 Load Cell (purchased
separately).
1. Insert the test die into the tool (refer to steps 3 and
4 under “Operation” in this manual). Position the
load cell so that the load cell piston is centered
between the two test dies.
2. Press the trigger until the crimping tool achieves
pressure relief and note the position of the needle
when the pressure relief is achieved. The needle
should indicate the “12T” range; if the needle is
outside of this range, send the crimping tool to an
authorized service center for adjustment.
Note: If some other type of load cell is used, the ratio
between the area of the tool and the area of the load cell
may be different. The appropriate corresponding pressure range depends upon this ratio.
Checking the Oil Level
1. Remove the two screws holding the tank housing
cover.
2. Remove the tank housing cover.
3. Point the cutting head towards the ground and
remove the oil plug. Add oil if necessary.
4. Replace the oil plug and the tank housing cover.
Secure with screws.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Relief valve adjustments must be done by an
authorized service center.
16
Page 17
Troubleshooting
E12CCX 12-ton Battery-powered, High-speed Tool
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.
Problem Probable Cause Probable Remedy
Tool is inoperative. Dirt, contaminants, etc., in ram area
of tool.
Crimping tool battery contacts
damaged.
Tool components worn or damaged. Return tool to an authorized
Dead battery. Charge or replace.
Dies and adapters stop during
operation.
Oil level is low. Check oil level. Rell reservoir.
Air in hydraulic system. Pull trigger and hold retract button
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.
Clean tool.
Reform contacts.
Greenlee service center.
simultaneously. Hold for approxi-
mately 10 seconds.
Battery load display ashes
constantly.
Tool loses oil. Damaged internal seal. Return tool to an authorized
Battery charge low. Charge or replace battery.
Greenlee service center.
Oil plug not installed properly. Rell reservoir and replace plug.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
17
Page 18
Disassembly
E12CCX 12-ton Battery-powered, High-speed Tool
Main Components
1. Remove the battery.
2. Remove the screw (17) and stop (18).
3. Unscrew and remove the universal head assembly.
4. Remove the piston (16). Replace the piston O-ring
(14) and piston backup ring (15).
5. Unscrew two tank cover screws (53) and remove
the tank cover (58).
6. Remove the hydraulic reservoir plug (76) and drain
the hydraulic uid.
7. Reinstall the plug.
8. Remove the remaining housing screws (51 and 53).
9. Remove the right housing half (59).
10. Remove the switch cover (56).
11. Lift the pump/motor assembly and circuit card
from the left housing half (60). Lift the LED from its
housing (8).
12. Slide a plastic bag over the circuit card and elec-
tronic subassemblies. Tape the bag shut to protect
the subassemblies from hydraulic oil and other
contamination.
13. Unscrew the shoulder bolt (99) and remove the
release lever (107).
14. Remove screws (108) and separate the gear
housing/motor subassembly from the pump
housing.
Pump
1. Use a hooked tool to remove the reservoir O-ring
(80). Gently tug it over the reservoir.
2. Remove the reservoir (74).
3. Remove the pump piston (152).
4. Remove the screw plug (151), washer (153), pump
piston (150), valve stem (156), and spring (155).
Replace the sealing washer (154).
5. Use a piece of tape to mark the side of the relief
that is facing up. (This is a reference point for reassembly.) Remove the unloading valve by
unscrewing the plug (126).
6. Remove the feeder tube subassembly by unscrewing the feeder tube (78). Replace the oil lter (77).
Remove metal chips from the magnet (82).
7. Remove the threaded bushing (72) and replace
the O-ring (73).
Motor, Gearbox, and Bearing
1. Remove the tamper-proof paper seal (96).
Remove two screws (92). Remove the end cap (102).
2.
3. Apply pressure evenly at three points around the
ball bearing (91) and gently pry the bearing up to
remove it.
4. Remove the eccentric (103), grooved ball bearing
(101), and snap ring (100) subassembly from the
shaft.
5. Remove four screws (93). Remove the mounting
block (109) from the gear housing (94).
6. Use a snap-ring removal tool to remove the snap
ring (100).
7. Unscrew four bolts (not numbered) from the gear
housing (94). Separate the gear housing from
the spacer (not numbered). Unscrew two Fillister
head screws (112) to separate the spacer from the
motor (90).
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
18
Page 19
Assembly
E12CCX 12-ton Battery-powered, High-speed Tool
Motor, Gearbox, and Bearing
1. Install two Fillister head screws (112) into the spacer
(not numbered) and motor (90). Tighten the screws.
2. Install four screws (not numbered) into the gear
housing (94). Tighten the screws.
3. Install four screws (93) into the mounting block (109)
and gear housing (94). Tighten the screws.
4. Replace the grooved ball bearing (101) and snap
ring (100) subassembly.
5. Replace the eccentric (103). Use a ber mallet to
tap the eccentric onto the shaft. Replace the ball
bearing (91).
6. Align the end cap (102). Use a ber mallet to tap the
cover until it is ush on the mounting block (109).
Install two screws (92).
7. Align the gear housing/motor subassembly so that
the pump piston (152) extends through the mounting block (109) and makes contact with the grooved
bearing (101). Locate and start the screws (108)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert the pump piston (152) into the pump housing.
2. I
nsert the seal (122) and unloading valve assembly
into the pump housing. Grasp the needle valve
subassembly by the pressure relief (126) and twist
it several turns clockwise. Stop when the piece of
tape is facing up.
3. Assemble the pump piston (150), valve stem (156),
washer (153), spring (155), and screw plug (151).
Be sure to replace the sealing washer (154). Torque
the screw plug (151) to 102 Nm (75 ft-lb).
4. Install the release lever (107) so that the forked end
engages the unloading valve subassembly between
the pressure relief (126) and the support ring (127).
Install the screw (99) and washer (104).
5. Insert the threaded bushing (79) and feed tube
subassembly (77, 78, 82). Screw in until snug.
6. Install the reservoir (74). Slip the O-ring (80) over
the reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing.
7. Insert the plug (76) into the reservoir.
Main Components
1. Remove the protective plastic bag from the
electronics subassembly. Insert the LED into the
LED bushing (8).
2. Lay the gear housing/motor subassembly into the
left half of the housing. Insert the circuit board into
the circuit board slot so that the wires and chip face
in the direction of the trigger.
3. Lay the wires into the case. Be sure that the wires
will not be pinched.
4. Guide the wires for the battery clip so that the
battery wires lay on top of the electronics box;
install the battery clip so the red wire is upward.
5. Install the trigger cover (56). Press and release the
trigger to be sure that it operates freely.
6. Locate the right housing half (59) on top of the left
housing half (60). Check for pinched wires.
7. Install the housing screws (51 and 53).
Note: The handle screw (51) must engage the
nut (52).
8. Install the retraction stop valve body (12) and
screw (13).
9. Install retraction stop spring assembly (17) and
screw (18).
10. Install the piston (16).
11. Replace the front head assembly. Twist the cutting
head base (31) until it stops; back off 3/4 of a turn.
Install the stop (18) and screw (17). Be sure that the
ing head assembly rotates freely approximately
crimp
350°.
12. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the ll plug
(76) and ll the reservoir with hydraulic oil.
13. Install the battery.
14. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir with hydraulic
oil. Replace the ll plug (76).
15. Replace the tank cover (58) and tank cover
screws (53).
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
19
Page 20
Illustration—Housing Unit
E12CCX 12-ton Battery-powered, High-speed Tool
9
58
53
53
59
11
8
60
7
56
53
5
51
52
57
6
12
10
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
17
18
14
15
16
20
Page 21
E12CCX 12-ton Battery-powered, High-speed Tool
Illustration—Head and Ram Unit
24
26
25
33
28
31
41
40
42
20
36
38
23
29
34
29
40
37
39
21
32
35
29
38
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
21
23
29
39
Page 22
E12CCX 12-ton Battery-powered, High-speed Tool
Illustration—Pump Housing, Reservoir Assembly, and Motor Assembly
90
110
94
112
113
74
76
71
82
75
77
78
79
83
80
70
122
81
123
129
121
124
120
155
130
125
126
156
127
128
150
154
153
99
151
105
152
107
108
100
109
103
93
102
101
96
91
92
141
140
73
72
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
22
Page 23
E12CCX 12-ton Battery-powered, High-speed Tool
Illustration—Punch Driver Adapter CCX
205
202
200
203
204
201
207
Illustration—Cylinder Assembly
211
210
208
206
218
217
212
215
213
214
216
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
23
Page 24
E12CCX 12-ton Battery-powered, High-speed Tool
Parts List
Key Part No. Description Qty
52031380 Retraction stop valve (includes 5, 6, 12, 13, 17, 18)
5* O-ring ........................................................................................................ 1
6* O-ring ........................................................................................................ 1
7 50067753 Circuit board, programmed ....................................................................... 1
8 50042416 Bushing LED ............................................................................................. 1
9 50111132 Decal, identication ................................................................................... 1
10 50111140 Decal, warning .......................................................................................... 1
11 50062140 Decal, pinch hazard .................................................................................. 1
12 Retraction stop valve body ....................................................................... 1
13 Screw, at head socket ............................................................................ 1
14* O-ring ........................................................................................................ 1
15* Backup ring ............................................................................................... 1
16 50067796 Piston ........................................................................................................ 1
17 Retraction stop spring assembly .............................................................. 1
18 Screw, socket head cap ............................................................................ 1
20 50111230 Spring, torsion ........................................................................................... 2
21 52020102 Adapter, U-type die set (UA12T) ............................................................... 1
∆ 23 F021776 Compression spring .................................................................................. 2
24 50066951 Screw ........................................................................................................ 2
25 50066919 Compression spring .................................................................................. 1
26 50066900 Disk ........................................................................................................... 1
28* O-ring ........................................................................................................ 1
29 90502507 Screw, cap ................................................................................................ 4
31 50111035 Fixed head ................................................................................................ 1
32 50111051 Movable head ........................................................................................... 1
33 50111060 Latch ......................................................................................................... 1
34 50111205 Plate .......................................................................................................... 1
35 50112244 Plate .......................................................................................................... 1
36 50111086 Pin, pivot ................................................................................................... 2
37 50111221 Piston ........................................................................................................ 1
∆ 38 50111183 Pin, adapter lock ....................................................................................... 2
∆ 39 50111159 Bushing ..................................................................................................... 2
40 90513533 Retaining ring ............................................................................................ 4
41 50043676 Screw, M5 x 10 ......................................................................................... 1
42 50066943 Stop........................................................................................................... 1
50013459 Housing unit (includes 51–60)
51 50042203 Screw ........................................................................................................ 1
52 50042211 Nut ............................................................................................................ 1
53 50042076 Screw ...................................................................................................... 12
56 Switch cover (black) .................................................................................. 1
57 Trigger guard ............................................................................................. 1
58 Reservoir cover ......................................................................................... 1
59 Housing, right side .................................................................................... 1
60 Housing, left side ...................................................................................... 1
50014200 Pump housing, reservoir assembly (includes 70–83)
†† 70 Ring tie ...................................................................................................... 1
†† 71 Cable tie .................................................................................................... 1
72 50041444 Threaded bushing ..................................................................................... 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
24
Page 25
E12CCX 12-ton Battery-powered, High-speed Tool
Parts List (cont’d)
Key Part No. Description Qty
73* O-ring ........................................................................................................ 1
†† 74 Hydraulic reservoir .................................................................................... 1
75 50041983 Ring ........................................................................................................... 1
†† 76 Reservoir plug ........................................................................................... 1
77* Filter .......................................................................................................... 1
78 50058827 Filter adapter ............................................................................................. 1
79 50058851 Threaded bushing ..................................................................................... 1
†† 80* O-ring ........................................................................................................ 1
81 50058290 Attachment ring......................................................................................... 1
82* Magnet ...................................................................................................... 1
83 Pump housing ........................................................................................... 1
50121758 Motor assembly (includes 90–98, 100–103, 108–112)
n 90 Motor with pinion ...................................................................................... 1
l o 91 Ball bearing ............................................................................................... 1
o 92 Screw ........................................................................................................ 2
o 93 Screw ........................................................................................................ 4
n 94 Gearbox (includes 113) ............................................................................ 1
o 96* Seal ........................................................................................................... 1
t 99 Screw, socket head ................................................................................... 1
l o 100 Retaining ring ............................................................................................ 1
l o 101 Grooved ball bearing ................................................................................. 1
o 102 End cap ..................................................................................................... 1
l o 103 Eccentric ................................................................................................... 1
t 105 Spring ........................................................................................................ 1
t 107 Release lever ............................................................................................. 1
o 108 Screw ........................................................................................................ 2
o 109 Eccentric case ........................................................................................... 1
n 110 Flange ...................................................................................................... 1
n 112 Screw ........................................................................................................ 2
113 52028323 Screw, gearbox ......................................................................................... 4
52031134 Relief valve assembly (includes 120–130)
120* Washer ...................................................................................................... 2
121* O-ring ........................................................................................................ 1
122* Seal ........................................................................................................... 1
123 50053630 Valve seat .................................................................................................. 1
124 Plunger ...................................................................................................... 1
125* O-ring ........................................................................................................ 1
126 Pressure relief ........................................................................................... 1
127 Support ring .............................................................................................. 1
128* Retaining ring ............................................................................................ 1
129 Needle valve .............................................................................................. 1
130 Spring ........................................................................................................ 1
140 50041266 Switch ....................................................................................................... 1
141 50041274 Battery contacts ........................................................................................ 1
143 Wire (not shown) ....................................................................................... 1
144 Wire (not shown) ....................................................................................... 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
25
Page 26
E12CCX 12-ton Battery-powered, High-speed Tool
Parts List (cont’d)
Key Part No. Description Qty
50013483 Piston pump assembly (includes 150–156)
150 Pump piston .............................................................................................. 1
151 Screw plug ................................................................................................ 1
152 Pump piston .............................................................................................. 1
153* Washer ...................................................................................................... 1
154* Sealing washer .......................................................................................... 1
155 Spring ........................................................................................................ 1
156 Valve stem ................................................................................................. 1
50118900 Punch driver adapter CCX (includes 200–208)
200 50112074 Piston ........................................................................................................ 1
201 50112031 Housing ..................................................................................................... 1
202 50112058 Piston stop ring ......................................................................................... 1
† 203 50041940 Backup ring, piston ................................................................................... 2
† 204 50041924 O-ring ........................................................................................................ 2
205 50041576 Screw ........................................................................................................ 3
† 206 50118919 Lock washer .............................................................................................. 1
207 50070169 Cap screw, M6x8 ...................................................................................... 1
208 50120085 Decal, identication ................................................................................... 1
210 50112040 Ram housing ............................................................................................. 1
211 50112066 Ram ........................................................................................................... 1
212 50112082 Piston ........................................................................................................ 1
213 50070193 Compression spring .................................................................................. 1
214 50041681 Screw ........................................................................................................ 2
215 50112090 Spacer ....................................................................................................... 3
216 50118897 Cap screw, M4x60 .................................................................................... 3
217 50041940 Backup ring, piston ................................................................................... 1
218 50041924 O-ring ........................................................................................................ 1
Kits
∆ 50118374 Adapter lock kit (includes items 23, 38, and 39)
† 50017420 Seal kit, punch adapter (includes items 203, 204, and 206)
52020102 UA12T, U-type die adapter set (includes two of item 21)
* 50118366 Seal kit (includes items marked with *)
t 50118927 Retraction lever assembly (includes 99, 105, 107)
†† 52028330 Reservoir kit (includes 70, 71, 74, 76 & 80)
n 52028329 Motor and gear box assembly
l 52028331 Eccentric bearing kit
o 52028332 Eccentric kit
50112171 Decal, connector
compatibility
50118358 Case with inserts
50070630 12 V battery NiMH
50030469 12 V charger 110 VAC
50030477 12 V charger 220 VAC
50030485 12 V charger 12 VDC
USA 800-435-0786 Fax: 800-451-2632
815-397-7070 Fax: 815-397-1865
Canada 800-435-0786 Fax: 800-524-2853
International +1-815-397-7070 Fax: +1-815-397-9247
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
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