Greenlee E12CCXL Operation Manual

Page 1

OPERATION MANUAL

GATOR® E12CCXL

Battery-powered Tool

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

12-ton

Page 2

E12CCXL 12-ton Battery-powered Tool

Table of Contents

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

Safety ............................................................................ 2

Purpose of this Manual ................................................. 2

Important Safety Information .....................................3–4

Identication .................................................................. 5

Specications ................................................................ 5

Operation ..................................................................6–15

Crimping Using KC12 or KA12 type U-style Dies...7–8

Crimping Using UA12ID Dieless Die Set ................... 9

Cutting ..................................................................... 10

Punching .............................................................11–15

Die Selection ............................................................... 15

Connector Selection .................................................... 15

Additional U-type Dies ................................................ 16

Available Accessories .................................................. 16

cUL and UL Classied Crimps .................................... 18

Connector Table .......................................................... 18

Maintenance ................................................................ 19

Troubleshooting ........................................................... 20

Description

The E12CCXL 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, 6,276,186, 6,401,515, 6,532,790, 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 tool:

E12CCXL 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.

Do not discard this product or throw away! For recycling information, go to www.greenlee.com.

All specications 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 Textron Innovations Inc.

Blackburn is a registered trademark of Thomas & Betts.

KEEP THIS MANUAL

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

Page 3

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, dened below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.

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.

E12CCXL 12-ton Battery-powered Tool

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 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 protective 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. 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.

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

Page 4

E12CCXL 12-ton Battery-powered Tool

IMPORTANT SAFETY INFORMATION

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 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.

• 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 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 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.

• 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 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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.

Page 5

Identiﬁcation

1. LED Work Light (white)

2. Adapter Release Buttons

3. Head

4. Latch (for opening head)

5. Lanyard Ring

6. Housing

7. Retract Button

8. LED Indicator (red)

9. Battery

10. Trigger

E12CCXL 12-ton Battery-powered Tool

Speciﬁcations

Tool

Length .....................................................16.5" (419.1 mm)

Width ......................................................... 2.87" (72.9 mm)

Height (with battery) ................................ 14.5" (368.3 mm)

Weight ............................................................15 lb (6.8 kg)

Crimping Force ....................................... 12 tons (106 kN)

Hydraulic Oil ....... 52057878 biodegradable hydraulic uid

Recommended Operating

Temperature Range ......... 5 °F to 122 °F (–15 °C to 50 °C)

Battery Charger

Read the instructions supplied with the battery charger

52047087 120 VAC corded adapter

52047088 230 VAC corded adapter

52049189 18 V, 3 Ah lithium-ion battery

52049201 120 VAC, 18 V charger

52049202 230 VAC, 18 V charger

52049204 12 VDC, 18 V charger

52054992 Li (18 V) to NiCd, NiMH (12 V)

charger adapter

50122746 Carrying strap

Crimping Capacities

Copper Color-Coded Lugs and Splices ............. 750 kcmil

Aluminum Color-Coded Lugs and Splices ......... 750 kcmil

UA12ID Dieless Die Crimping Range

Copper Color-Coded

Lugs and Splices .............................. 4 AWG–750 kcmil

Aluminum Color-Coded

Lugs and Splices .............................. 6 AWG–600 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

Tension Splices ...................................4 AWG–556.5 kcmil

Two-Piece ACSR

Tension Splices ...................................2 AWG–556.5 kcmil

Cutting Capacities

Copper and Aluminum Cable .................... 1-1/2" (40 mm)

ACSR ...................................................954 kcmil (Cardinal)

Standard Guy Strand ................................................... 5/8"

EHS Guy Strand ...........................................................1/2"

Ground Rod ...................................................1/2" (13 mm)

Rebar (schedule 60) .......................................1/2" (13 mm)

Threaded Rod ............................................ 1/4", 3/8", 1/2"

Punching Capacities

Round .....................5-5/8" (144.1 mm) in 10 ga. mild steel

Rectangular .......... 2.677" x 5.433" (68.0 mm x 138.0 mm)

Square ................5.433" x 5.433" (138.0 mm x 138.0 mm)

Accessories required to punch ø 4" through ø 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

Page 6

Operation

E12CCXL 12-ton Battery-powered Tool

• 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.

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.

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.

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.

• Use this tool for the manufacturer’s intended purpose only.

Failure to observe these precautions may result in injury or property damage.

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:

What happens Signal What it means

Flashing light for 2seconds Battery is inserted in tool

Constant light for 20seconds at end of cycle

Tool will not start, and constant light for 20seconds when trigger is released

Tool will stop, and constant light for 20seconds after trigger is released

Tool will stop, and ﬂashing light for 20seconds when trigger is released

Battery charge is below 17V at beginning of cycle

Battery charge is below 16V at beginning of cycle

Battery voltage drops below 13V during cycle

Motor current exceeds 20A during cycle

Circuit has become too hot

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

Page 7

E12CCXL 12-ton Battery-powered Tool

Operation —Crimping Using KC12 or KA12 type U-style Dies

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 UA12T adapters and U-style 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.

Press detents and slide UA12T adapters into place as shown. Release to lock.

Preparing the Cable

Follow the lug manufacturer’s instructions for appropriate cable strip length.

CRIMPING DIRECTION

1ST COMPRESSION

CRIMPING DIRECTION

SIDE B

1ST COMPRESSION

SIDE A

1ST COMPRESSION

CRIMPING DIRECTION

SIDE A

SIDE B

Slide U-style dies into adapters until dies snap into place.

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

Page 8

E12CCXL 12-ton Battery-powered Tool

Operation —Crimping Using KC12 or KA12 type U-style Dies (cont’d)

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. Improper combinations can result in an incomplete crimp.

Failure to observe these warnings could result in severe injury or death.

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.

Retraction Stop

1. To stop the ram from returning fully, activate the trigger for a brief moment. This activation will close the retraction valve, stop the retraction motion, and set the semi-automatic retraction stop position.

2. Depress the trigger to advance the ram. Hold the trigger down until the ram automatically retracts. The ram will partially retract to the set position and allow the tool to be repositioned.

3. If full retraction is desired, release the trigger at the end of the crimp.

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

Page 9

E12CCXL 12-ton Battery-powered Tool

Operation—Crimping Using UA12ID Dieless Die Set

Setup

1. Open the tool head.

2. Remove any accessories from the tool head.

3. Install the UA12ID indenter against the ram and lock in place with the detent.

4. Install the UA12ID anvil into the head and lock in place with the detent.

Important: The indenter and anvil must be locked

into place or the detents will be damaged.

5. Visually check the indenter and anvil to ensure that they are aligned correctly so that they will complete the crimping operation.

6. Close the tool head.

Press detent and slide UA12ID indenter into place as shown. Release to lock.

Press detent and slide UA12ID anvil into place as shown. Release to lock.

Preparation

3. If open, close the crimping head. Make sure the head and latch are fully engaged.

4. For a cUL or UL classied crimp, complete the number of crimps specied under “Connector Table” in this manual.

5. For a single crimp, position the connector so the crimp will be located at the center of the barrel. For a double crimp, position the connector so two crimps will be evenly spaced between the connector marks.

6. Depress the trigger to advance the indenter. Hold the trigger down until the indenter automatically begins to retract.

Notes: If the crimping tool does not automatically retract, the crimp is incomplete.

It is normal for the battery load display to light at both the beginning and near the end of the crimping cycle.

7. Release the trigger until the indenter retracts completely.

8. To stop the ram from returning fully, activate the trigger for a brief moment. This activation will close the retraction valve and stop the retraction motion.

9. Lift the latch to open the crimping head and remove the connector.

Note: If it is necessary to retract the indenter before a crimp cycle is complete, push the retract button. Pushing the retract button will result in complete retraction of the indenter.

After completing the last crimp on an aluminum connector, wipe off the excess oxide inhibitor.

For a cUL or UL classied crimp, refer to “Connector Table” in this instruction manual.

1. Select a proper size and type of connector to correspond with the wire or cable.

2. Strip the cable to an appropriate length. Follow the connector manufacturer’s instructions.

Note: Apply an oxide inhibitor, if required. Refer to the connector manufacturer’s instructions.

3. Clean the die seat area.

Crimping Procedure

1. Insert the cable fully into the connector.

An incomplete crimp can cause a re.

• Use proper die, connector, and cable combinations. Improper combinations can result in an incomplete crimp.

Failure to observe these warnings could result in severe injury or death.

2. Place the connector into the V of the crimping head as shown below.

Automatic Retraction Stop

1. Depress the trigger to advance the indenter. Hold the trigger down until the indenter automatically retracts. The indenter will partially retract to allow the tool to be repositioned.

Connector

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

2. If full retraction is desired, release the trigger at the end of the crimp.

Page 10

Operation —Cutting

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.

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.

E12CCXL 12-ton Battery-powered Tool

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

UC26

UC40

UCACSR

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.

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

Page 11

Operation—Punching

E12CCXL 12-ton Battery-powered Tool

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.

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 withstand 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

Page 12

Operation—Punching (cont’d)

E12CCXL 12-ton Battery-powered Tool

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.

13. Pull the trigger.

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.

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

Page 13

Operation—Punching (cont’d)

E12CCXL 12-ton Battery-powered 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

Page 14

Operation—Punching (cont’d)

Punch Driver

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

E12CCXL 12-ton Battery-powered Tool

60114

1/4" Adapter

60115

1/4" Draw Stud

03248

Spacer

End with Long Threads

Die

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

05244

1/4" Counter Nut

Punch

04638

3/8" Counter Nut

Punch

Pilot Hole

Punch Driver

33967

3/8" Adapter

60116

3/8" Draw Stud

03248

Spacer

End with Long Threads

Threads with Flats

Die

Punch Driver

60167

1/2" Adapter

60117

3/8" Draw Stud

03248

Spacer

End with Long Threads

Threads with Flats

Die

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

Pilot Hole

60258

1/2" Counter Nut

Page 15

E12CCXL 12-ton Battery-powered Tool

Operation—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

Page 16

E12CCXL 12-ton Battery-powered 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 classied when used with the appropriate conductor and connectors listed below.

Dies for Copper Connectors

Catalog

No.

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

UPC

No.

Cable

Size

Color Code

No. of

Crimps

Dies for Aluminum Connectors

Catalog

No.

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

UPC

No.

Cable

Size

Color Code

No. of

Crimps

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 classied for use with the following connector brands:

CONNECTOR

TYPE

Copper Splices

Copper

Lugs

BARREL

TYPE

Short

Long

Short

Long

ANDERSON

VHSS

VHS

VHCS

VHCL

BLACKBURN

CSP

CTL-2/CTL

CTL-L/LCN

BURNDY

YS-L

YA-2LN/ YA-L/YA-2L; YA/YA-L-TC/

YA-L-2TC

YA/YAZ

YA-2N/YA-2TC

YAZ-2N/YAZ-2TC

ILSCO

CTL

CSW

CRA/CRB

CRC

CLN, CLW

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

When used with KA12-type dies, this tool is cUL and UL classied for use with the following connector brands:

CONNECTOR

TYPE

Dual-rated

Aluminum

Splices

Dual-rated

Aluminum

Lugs

ANDERSON

VACS

VACL

BLACKBURN

ASP

ATL

BURNDY

YS-A

YA-A

YA-ATN

ILSCO

ASN

ACL/ACN

2ACL/2ACN

ALNS/ALNN/ALND

PANDUIT

LAA LAB

T&B

60501 to

60578

60101 to

60176;

60230 to

60278

BCU

BBCU

BLU

BBLU

PENNUNION

PIK

BLUA

NUMBER

OF CRIMPS*

8 AWG to

250 kcmil:

1 crimp

300 to

750 kcmil:

2 crimps

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

95R7

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

Page 17

E12CCXL 12-ton Battery-powered Tool

Additional U-type Dies

Greenlee

Catalog 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

Greenlee UPC No.

FCI Burndy

No.

Available Accessories

Adapter

UC26 50067141

UC40 50070363

UCACSR 50070371

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

UA12P 50118900 Punch driver adapter

04686 50046861 Die bushing*

12185 50121855 Spacer*

03170 50031708 Punch sleeve, 1-1/8"*

UA12T 52020102 Adapter for U-type dies

UA12ID 52061814 Dieless die set

Required for knockout punches larger than 4" actual diameter.

Greenlee

Part No.

Description

Cutter blades for copper and aluminum 26 mm (1") max.

Cutter blades for copper and aluminum 40 mm (1-1/2") max.

Cutter blades for ACSR, ACAR, standard guy wire, EHS guy wire, copperweld, ground rod, anchor rod, soft bolts, rebar

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

Page 18

E12CCXL 12-ton Battery-powered Tool

cUL and UL Classiﬁed Crimps

Crimps made with the Greenlee UA12ID dieless die and E12CCXL crimping tool are cUL and UL classied on standard concentric, compressed, or compact stranded copper and aluminum cable with the connectors listed here.

Refer to the and model numbers of appropriate connectors and the number of crimps required.

Connector Table (NOT for use with ﬂex, navy or welding wire)

“Connector Table”

for the brand names

UA12ID

Dieless Die Set

Range: Copper Connectors—4 AWG to 750 kcmil Aluminum Connectors—6 AWG to 600 kcmil

COPPER CONNECTOR TYPE ANDERSON BLACKBURN

Copper Splices

Copper Lugs

*Number of

Crimps

ALUMINUM CONNECTOR TYPE ANDERSON BLACKBURN

Dual-Rated Aluminum Splices VACS ASP YS-A

Dual-Rated Aluminum Lugs VACL ATL

*Number of

Crimps

Copper Cable Size:

4 AWG–750 kcmil

Cable Size: 6 AWG–500 kcmil 1 1 1 1 1 1 1

Cable Size: 600 kcmil 2 1 1 1 2 1 1

VHSS

VHS

VHCS VHCL

1 1 1 1 1 1 1 1

CSP

CTL

CTL-L

LCN

BURNDY ILSCO PANDUIT T & B

YS-L

YA, YA-L, YA-2L YA-2LN, YA-2N

YA-L-TC, YA-L-2TC

YA-2TC, YAZ

YAZ-2N, YAZ-2TC

BURNDY ILSCO PANDUIT T & B

YA-A

YA-A-TN

CTL

CLN, CLW, CSW CRA, CRB, CRC

CRA-L, CRB-L

CRA-2L CRB-2L CRC-2L

ASN

ACL, ACN 2ACL, 2ACN ALNS, ALNN

ALND

SCSS

SCS

SCL, SCH

LCAS

LCA LCB

LCD, LCC

LCAN

SA 60507 to 60584

LAA LAB

54506 to 54528 54806 to 54828

54106 to 54128 54206 to 54228

54906BE to

54928BE

54854BE to

54882BE

60106 to 60184 60230 to 60284

PENN-

UNION

BCU

BBCU

BLU

BBLU

PENN-

UNION

PIK

BCUA

BLUA

TYCO (AMP)

—

1099898-2 to 1-1099898-5 1099899-2 to 1-1099899-9 1099939-1 to 1-1099939-5

* When crimping with the UA12ID dieless die set, use the number of crimps listed in this table

instead of the number provided with the connector.

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

Page 19

Maintenance

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.

E12CCXL 12-ton Battery-powered Tool

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 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.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

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.

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.

Annually or After 10,000 Crimps

1. Replace the hydraulic oil.

2. Send the tool to a Greenlee Authorized Service Center for inspection.

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.

Periodic Pressure Relief Valve Check

The crimping tool’s relief valve may require occasional adjustment. To determine whether this adjustment is necessary, periodically send the tool to an authorized service center.

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 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 20

Troubleshooting

E12CCXL 12-ton Battery-powered 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.

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

Clean tool.

oftool.

Tool battery contacts damaged. Reform contacts.

Tool components worn or damaged. Return tool to a Greenlee Authorized

Service Center.

Motor is inoperative. 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 Authorized

Service Center.

Motor runs but tool will not complete a cycle.

Oil level low. Return tool to a Greenlee 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 Authorized Service Center.

Cold oil. Pull trigger and hold retract button

simultaneously to warm oil. Store tool in warm area.

Dies stop during operation. Oil level low. Return tool to a Greenlee 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 Authorized

Service Center.

Note: For Warranty Service or Repair, contact Greenlee customer service at 800-435-0786.

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