Greenlee EK1550FLT, EK1550FLX Operation Manual

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Page 1

OPERATION MANUAL

Serial Number

EK1550FLT and EK1550FLX

GATOR® Battery-powered,

15-ton Crimping Tools

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

Page 2

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

Table of Contents

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

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

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

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

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

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

Adapter Kits .................................................................... 6

Setup .............................................................................. 7

Operation .................................................................... 7–8

Die Selection .................................................................. 9

Connector Selection ....................................................... 9

LCD Screen .................................................................. 10

Maintenance ................................................................. 11

Troubleshooting ............................................................ 12

Description

The EK1550FLT and EK1550FLX Battery-powered, 15-ton, High-speed Crimping Tools are hand-held, selfcontained crimping tools intended to crimp aluminum and copper connectors onto electrical cable.

These tools have a retraction stop feature which allows the operator to stop the retraction motion of the ram to shorten cycle time.

Both the T and X versions of this tool have Bluetooth® connectivity and an LCD screen. Only the T version has GPS tracking.

These tools are protected by U.S. Patent No. 6,206,663, 6,276,186, 6,401,515, and 6,718,870.

EK1550FLT—FCC ID: 2AGL2COM; IC ID: 20646COM EK1550FLX—FCC ID: 2AGL2CFM; IC ID: 20646CFM

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

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 tools:

• EK1550FLT Battery-powered Crimping Tool

• EK1550FLX Battery-powered Crimping Tool

Keep this manual available to all personnel.

Replacement manuals are available upon request at no charge at www.greenlee.com.

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

All 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 is a registered trademark of Textron Innovations Inc.

Bluetooth is a registered trademark of Bluetooth SIG, Inc.

Blackburn is a registered trademark of Thomas & Betts.

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

KEEP THIS MANUAL

Page 3

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

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.

Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.

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.

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.

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.

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.

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

Page 4

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

IMPORTANT SAFETY INFORMATION

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.

Remove the battery before transporting the T version of this tool by air.

Failure to observe this warning could result in severe injury or death.

• Inspect tool and dies before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel.

• Carrying strap is for carrying only, not to be used to hang or suspend tool.

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

• Do not use this tool for continuous use. After 30 to 40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is designed for hand-held operation.

• This tool may be used in damp or wet environments; however, air-drying is recommended before use if the tool becomes soaked. Damage may result when the tool is operated prior to thorough drying when electrical components are soaked.

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

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

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 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

Page 5

Identiﬁcation

1. Die Release Buttons

2. Lanyard Ring

3. Housing

4. Retract Button

5. LED Indicator (red)

6. LCD Screen

7. Battery

8. Trigger

9. LED Work Light (white)

10. Pull Pin

11. Ram

12. Flip-top Head

13. Handle

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

Speciﬁcations

Crimping Tool

Length ......................................................19.00" (483 mm)

Width ............................................................ 3.00" (76 mm)

Height (with battery) ................................... 13.5" (342 mm)

Mass/Weight (with battery) .......................18.2 lb (8.25 kg)

Crimping Force ........................................ 15 tons (135 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

Crimping Capacities

Maximum Crimping Capacity

Aluminum ..................................................... 1250 kcmil

Copper ......................................................... 1500 kcmil

With “P” Style Dies (no adapter kit needed): 1250 kcmil aluminum and 1500 kcmil copper ttings

With 52060610 Die Adapter Set for 12-ton “U” Style Dies: 500 kcmil copper splices, 750 kcmil copper terminals, 350 kcmil aluminum splices, 750 kcmil aluminum terminals

Note: Do not use non-butting dies (crimps controlled by tonnage) in this tool, as damage could occur to connectors and/or conductors.

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

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EK1550FLT and EK1550FLX Battery-powered Crimping Tools

Adapter Kits

Procedure for Using Burndy Y46 Dies and “P” Style Dies

1. No die holder assemblies are needed. Dies t directly into tool.

2. Select proper die set for tting to be crimped.

Note: Do not use non-butting dies (crimps controlled by tonnage) in this tool, as damage could occur to connectors and/or conductors.

3. Slide top die into place in die holder while simultaneously squeezing retainer button. Release button and allow die to snap into place. Repeat operation for other die entry.

Top Die Retaining Mechanism

Bottom Die Retaining Mechanism

Procedure for Using 12-ton “U” Style Dies with 52060610 Die Adapter Set

1. Slide a die adapter assembly into the ip-top head while depressing the die retainer button. Release the retainer button while the adapter snaps into place. The die adapter should be locked in position.

2. Repeat Step 1 to install the other die adapter into the ram end.

3. Select the proper “U” die set for the connector to be crimped.

4. Slide the “U” die into the die adapter while depressing the die retainer button. Release the die button while it snaps into place, locking the die into position.

5. Repeat Step 4 with other “U” die.

Top Die Retainer Button

12-ton “U” Die Adapter Set UA15T (52060610) (contains two die adapters)

Bottom Die Retainer Button

Die Retainer Button (UA15T)

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

Page 7

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

Setup

1. Select the die set that corresponds to the size, type,

and manufacturer of connector to be crimped.

2. Determine if the die adapter set is required:

• “P” style dies—no die adapters required

• 12-ton “U” style dies—52060610 die adapter set

3. Install proper size crimping dies in crimping head.

Be sure die seat area is clear of debris.

Operation

• Inspect tool and dies before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel.

• Carrying strap is for carrying only, not to be used to hang or suspend tool.

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

• Do not use this tool for continuous use. After 30 to 40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is designed for hand-held operation.

• 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.

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.

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

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

Flashing light for 20 seconds at end of cycle

* Running the battery below 16 V can damage the battery.

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

Send tool in for service

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

Page 8

Operation (cont’d)

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

Pressure Sensor

This tool is equipped with a pressure sensor that alerts the user of an incomplete crimp.

• If the tool is manually retracted before completion of a crimp, the red LED and an audible beep will be active for 2 seconds.

• If the tool is unable to reach the required crimp force, the red LED, work light, and an audible beep will pulse until after the trigger is released.

For a cUL or UL classied crimp, see the connector table in this instruction manual.

Preparation

Note: When using KC12-type dies, complete the number of crimps listed on the “Connector Selection” chart in this manual. For other dies, complete the number of crimps speciﬁed by the manufacturer.

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. See the connector manufacturer’s instructions.

3. Clean the die seat area.

Crimping

1. Insert the cable fully into the connector.

2. If open, close the ip-top head and engage the pull

pin. Make sure the pull pin is fully engaged.

3. Align the connector between the crimping dies as

shown below.

5. For a single crimp, position the connector so the crimp will be located at the center of the barrel.

Crimping Direction

(evenly spaced)

First Compression

Crimping Direction

SIDE B

(evenly spaced)

First Compression

SIDE A

First Compression

Crimping Direction

SIDE A

(evenly spaced)

SIDE B

6. Depress the trigger to advance the ram. Hold the trigger down until the ram 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 ram 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.

Note: if it is necessary to retract the ram before a crimp cycle is complete, 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.

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

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

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.

Page 9

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

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

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

Splice

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

BBCU

BBLU

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

Splice

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

PennUnion

BLUA

BCU

BLU

PIK

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 10

LCD Screen

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

This tool has an LCD screen, which displays information about the tool. Turn on the screen by inserting the battery and jogging the tool. If there are any problems with the tool, an error code appears.

Error Code Meaning

1 Overcurrent fuse

2 Overcurrent comparator

3 Overheated circuit board

4 Overheated battery

5 Battery empty; operation stops

6 Faulty crimp; complete cycle

7 Faulty crimp; incomplete cycle

8 Low battery

9 Battery empty; tool won’t run

10 Real-time clock battery low

11 Tool deactivated

12 Service necessary

13 Real-time clock not found

14 Bluetooth® unit not found

15 Mobile unit not found

16 Pressure sensor not found

17 Burst pressure exceeded

18 Battery temperature too low

If there is no error code, cycle through the various displays using the left and right buttons on either side of the screen. There are seven displays in total.

Display Information Shown

Bluetooth® status, battery charge, current

pressure, max. pressure

Firmware, available rmware update,

serialnumber

Current user. Press and hold both buttons to

change user, select with right button, and conrm by jogging the tool.

4 GSM/CDMA signal strength

5 GPS signal status

6 Cycles until next service

Since manufacturing: operating hours, capacity,

number of cycles

Note: Tool data transmission starts with production of the tool, independent of registration on i-connect, but only for the T version of this tool.

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

Page 11

Maintenance

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

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.

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, contact Greenlee customer service at 800-435-0786 for warranty service or repair.

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

Thoroughly clean all surfaces.

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.

Relief valve adjustments must be done by an authorized service center.

Annually or After 10,000 Crimps

Contact Greenlee customer service at 800-435-0786 for warranty service or repair, and hydraulic oil replacement.

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

Page 12

Troubleshooting

EK1550FLT and EK1550FLX Battery-powered Crimping Tools

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. Battery charge low. Charge or replace battery.

Dirt, contaminants, etc., in

Clean tool.

ram area oftool.

Tool components worn or damaged.

Contact Greenlee customer service at 800-435-0786 for warranty service or repair.

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. Contact Greenlee customer service at

800-435-0786 for warranty service or repair.

Motor runs but tool will not complete a cycle.

Oil level low. Contact Greenlee customer service at

800-435-0786 for warranty service or repair.

Air in hydraulic system. Pull trigger and hold retract button simultane-

ously. Run for approximately 10 seconds, and then attempt to crimp. If unsuccessful, contact Greenlee customer service at 800-435-0786 for warranty service or repair.

Cold oil. Pull trigger and hold retract button simultaneously

to warm oil. Store tool in warm area.

Tool loses oil. Damaged seal. Contact Greenlee customer service at

800-435-0786 for warranty service or repair.

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