Thomas & Betts EK22GL User Manual
INSTRUCTION MANUAL
GATOR® EK22GL
Battery-powered,
High-speed Crimping Tool
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 4521.5 © 2001 Greenlee Textron IM 1552 10/01
EK22GL Battery-powered, High-speed Crimping Tool
Table of Contents
Description .....................................................................2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
Important Safety Information......................................3–4
Identification ................................................................... 5
Specifications ................................................................. 5
Operation ................................................................... 6–7
Dies and Connectors...................................................... 8
Maintenance................................................................... 9
Troubleshooting ........................................................... 10
Disassembly.................................................................11
Assembly...................................................................... 12
Illustrations ............................................................. 13–15
Parts List ................................................................16–18
Description
The EK22GL Battery-powered, High-speed Crimping
Tool is a hand-held, self-contained crimping tool
intended to crimp copper cable with K22-type and
W-type dies.
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:
EK22GL Battery-powered, High-speed
Crimping Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge.
All specifications are nominal and may change as design improvements occur. Greenlee Textron shall not be liable for damages
resulting from misapplication or misuse of its products.
GATOR is a registered trademark of Greenlee Textron.
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 Textron / Subsidiary of Textron Inc. 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
EK22GL Battery-powered, High-speed Crimping 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, defined 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.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
Skin injection hazard:
Do not use hands to check for oil
leaks. High pressure oil easily
punctures skin causing serious
injury, gangrene, or death. If injured,
seek medical help immediately to
remove oil.
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 can
result in severe injury or death.
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning can
result in severe injury or death.
Do not use solvents or flammable
liquids to clean the crimping tool.
Solvents or flammable liquids could
ignite and cause serious injury or
property damage.
An incomplete crimp can cause a fire.
• Use proper die, connector, and cable combinations. Improper combinations can result in an
incomplete crimp.
• Use only W-type dies on aluminum connectors or
aluminum wire. Mismatched components can
result in an incomplete crimp.
• The relief valve will sound to indicate a completed
crimp. If you do not hear the sound of the relief
valve, the crimp is not complete.
Failure to observe these warnings can result in
severe injury or death.
Greenlee Textron / Subsidiary of Textron Inc. 3 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
EK22GL Battery-powered, High-speed Crimping Tool
Greenlee Textron / Subsidiary of Textron Inc. 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
IdentificationIdentification
EK22GL Battery-powered, High-speed Crimping Tool
10
11
1. Housing
2. Retract Button
3. Battery Cartridge
4. Trigger
5. Battery Load Display
6. Locking Flange
7. Die Release Buttons
8. W-type Die Detents
9. Crimping Dies
10. Crimping Head
11. Oil Reservoir
12. Oil Plug
Specifications
Crimping Tool
Length........................................................................................... 314 mm (12-3/8")
Width........................................................................................................76 mm (3")
Height ........................................................................................... 298 mm (11-3/4")
Mass/Weight (with battery) ................................................................. 4.4 kg (9.7 lb)
Sound Level..............................................................................75 dB (A) at 1 meter
Vibration.................................................................................................... < 2.5 m/s
Motor Type....................................................................... DC permanent field motor
Motor Voltage ...............................................................................................12 VDC
Hydraulic Oil ....................................................50 ml (0.1 pint) of Shell Tellus® T 15
Crimping Capacities
Maximum Cable Size.................................................................... 600 Kcmil copper
Maximum Crimping Force................................................................55 kN (6.2 tons)
Crimping Time ..........................................................................................7 seconds
Crimps per Charge ......................................................................approximately 120
Battery
Charging Voltage ............................................................................................... 12 V
Charging Time ................................................................................................ 1 hour
7
EK22GL
6
5
2
4
3
1
2
Greenlee Textron / Subsidiary of Textron Inc. 5 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
Operation
EK22GL Battery-powered, High-speed Crimping Tool
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning can
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
Charging the Battery
Read the instructions supplied with the battery charger.
Battery Condition
Battery Load Display Battery Condition
Momentary illumination at Normal or operating
beginning of crimp charge level
Flickering at point of Normal or operating
maximum crimping force charge level
Flickering during entire
crimping cycle
Constant illumination when
operating without a load
Low charge level
Low charge level
Installing K22-type Dies
1. Select the proper dies for the intended crimp.
2. Push the die release button.
3. Slide the die into the crimping head until it “snaps”
into place.
4. Properly position the second die. Repeat Steps
2 and 3.
Keep hands away from the crimping
head when crimping.
Failure to observe this warning can
result in severe injury or death.
• Do not operate the tool without dies. Damage to
the ram or crimping head can result.
• Do not operate with the crimping head open.
Damage to the ram or seals can result.
• This tool is not designed for continuous use.
After 30 to 40 crimping cycles, allow the crimping
tool to cool for 15 minutes.
• Do not place the tool in a vise. The crimping tool
is designed for hand-held operation.
• Protect the crimping tool from rain and moisture.
Water will damage the crimping tool and battery.
• Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions can result in
injury or property damage.
Installing W-type Dies
1. Push the die release button.
2. Slide the die adapter (Greenlee part number
500 4292.0) into crimping head until it “snaps”
into place.
Note: The die adapters have the “D3” die profile.
No additional dies are needed if the connector to be
crimped requires a “D3” die.
3. Repeat for the other adapter.
4. Select the proper dies for the intended crimp.
5. Press the locking flange and open the crimping
head.
6. Push the W-type die detent and slide the W-type die
into place.
7. Properly position the second die. Repeat Steps
5 and 6.
Greenlee Textron / Subsidiary of Textron Inc. 6 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
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