Greenlee GATOR EK06AT User manual

GATOR™
EK06AT and EK06ATC
BATTERY-POWERED
CRIMPING TOOLS
INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 3088.9 © 1999 Greenlee Textron IM 1367 8/99

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
Table of Contents
Description
The EK06AT and EK06ATC Battery-Powered Crimping
Tools are hand-held, self-contained dieless crimping
tools intended to crimp aluminum and copper connec-
tors onto electrical cable.
The EK06ATC has a rubber coated head.
Purpose
This instruction manual is intended to familiarize opera-
tors and maintenance personnel with the safe operation,
troubleshooting and repair procedures for the Greenlee
EK06AT and EK06ATC.
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
and are registered trademarks
of Greenlee Textron.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any decals 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.
KEEPTHIS MANUAL
Description .....................................................................2
Purpose..........................................................................2
Important Safety Information ......................................3-4
Identification...................................................................5
Location of Decals .........................................................6
Specifications.................................................................6
Operation ....................................................................7-8
Periodic Pressure Relief Valve Check...........................9
Maintenance ..................................................................9
Troubleshooting ...........................................................10
Service
Disassembly ..........................................................11
Assembly ...............................................................12
Exploded Views ......................................................13-15
Parts List .................................................................16-18

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
IMPORTANT SAFETY INFORMATION
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.
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.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in severe
injury or death.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
SAFETY
ALERT
SYMBOL
Skin injection hazard:
Oil under pressure easily punctures
skin causing serious injury, gangrene
or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Do not use hands to check for
leaks.
• Depressurize the hydraulic system
before servicing.
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.
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.
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 connector and cable combinations.
Improper combinations can result in an incom-
plete 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. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
IMPORTANT SAFETY INFORMATION
Do not dispose of batteries in a fire. Batteries will
vent harmful vapors and may explode.
Failure to observe this warning can result in
severe injury or death.
Inspect tool before use. Replace any worn or dam-
aged parts. A damaged or improperly assembled
tool can break and strike nearby personnel.
Failure to observe this warning can result in severe
injury or death.
• Do not store the battery at more than 60°C
(140°F). Damage to the battery can result.
• Do not attempt to open the battery. It contains
no user-serviceable parts.
• Do not charge the battery with another type of
charger. Other chargers may overcharge and
damage the battery.
Failure to observe these precautions can result in
injury or property damage.
Note: Keep decals clean and legible. Replace decals
when necessary.
• Keep hands away from the
crimping tool head when crimping.
• Lock trigger when not in use.
Failure to observe these warnings
can result in severe injury or death.
• Do not operate the tool without a connector in
place. Damage to the ram or crimping tool head
can result.
• This tool is not designed for continuous use.
After 30-40 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.
Do not allow any object to contact the battery
terminals.
• Do not immerse 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 can result in
injury or property damage.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
Identification
EK06AT
1. Trigger 5. Crimping Head
2. Trigger Lock 6. Housing
3. Battery 7. Battery Load Display
4. Retract Button 8. Hand Guard
5
6
7
1
2
8
3
4

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
Crimping Tool
Length.........................................................................................355 mm (14")
Width ..........................................................................................355 mm (14")
Height .............................................................................................76 mm (3")
Mass/Weight (with battery)..............................................5.03 kg (11 lbs 1 oz)
Sound Level .................................................................... 75 dB (A) at 1 Meter
Vibration .................................................................................(< or >) 2.5 m/s2
Motor Type ..........................................Direct-Current Permanent Field Motor
Motor Voltage ...................................................................................... 12 VDC
Hydraulic Oil ........................................................ ml (pint) of Shell Tellus T15
Crimping Capacities
Cable Size (Aluminum or Copper) ................................. (#8 AWG - 500 MCM)
Crimping Force.......................................................................55 kN (6.2 tons)
Crimping Time ................................................................................ 7 Seconds
Crimps per Charge ...................................................Approximately 40/charge
Battery
Charging Voltage...................................................................................... 12 V
Charging Time.......................................................................................1 Hour
Specifications

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
Operation
Charging the Battery
Read the instructions supplied with the battery charger.
Battery Condition
Preparation
Follow the lug manufacturer’s instructions for appropriate
cable strip length.
Battery Load Display Battery Condition
Momentary illumination Normal
at beginning of crimp
Flickering at end of crimp Normal
Flickering during entire crimp Low charge
Constant illumination Low charge
during entire crimp
CRIMPING DIRECTION
1ST COMPRESSION
CRIMPING DIRECTION
SIDE A
CRIMPING DIRECTION
SIDE B
1ST COMPRESSION
SIDE A
1ST COMPRESSION
SIDE B

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
Inspect tool 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 can result in severe
injury or death.
• Keep hands away from the
crimping tool head when crimping.
• Lock trigger when not in use.
Failure to observe these warnings
can result in severe injury or death.
1. Insert cable fully into connector. Center the connec-
tor between the nibs.
2. Pull the trigger to advance the nibs. Hold the trigger
down until the pressure relief valve activates.
Note: Pressure relief occurs at approximately 690
Bar (10,000 psi) and is indicated by an
audible “pop”.
3. After achieving pressure relief, the ram will auto-
matically return to the start position and the nibs
will retract.
4. Complete the number of crimps specified by the
connector manufacturer.
Small connectors may become
wedged between the nibs of
the tool. Center the connector
between the four nibs before
crimping.
Failure to observe this precaution
can cause property damage.
Operation (cont’d)
Electric shock hazard:
The EK06AT 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.
An incomplete crimp can cause a fire.
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 this warning can result in severe
injury or death.
Crimping
Wear eye protection when operating
this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
RIGHT
WRONG

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
Maintenance
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.
Periodic Pressure Relief Valve Check
Test the crimping tool periodically to ensure that the
pressure relief valve activates at the proper pressure.
Testing the Crimping Tool
1. Center a test slug between the nibs.
2. Pull the trigger to advance the nibs. Hold the trigger
down until the pressure relief valve activates.
3. After achieving pressure relief, the ram will auto-
matically return to the start position and the nibs will
retract.
4. Evaluate the test slug as follows:
• If the test slug does not fit into GO slot, the
pressure relief valve is set too high. Send the
crimping tool to an authorized Greenlee service
center.
• If the test slug fits into the GO slot, the pressure
relief valve is set correctly.
• If the test slug fits into the NO GO slot, the
pressure relief valve is set too low. Send the
crimping tool to an authorized Greenlee service
center.
1. Inspect nibs for wear or damage such as cracks,
gouges or chips.
2. Inspect the crimping tool for damage or leaks. Have
a damaged or leaking crimping tool repaired at an
authorized Greenlee service center.
After Each Use
1. Wipe all tool surfaces clean with a damp cloth and
mild detergent.
2. Fully retract and lock the trigger. Place the crimping
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.
Annually or Every 10,000 Crimps
1. Change the hydraulic oil.
2. Return the tool to an authorized Greenlee service
center for inspection.
Checking the Oil Level
1. Remove the two screws (215) that retain the tank
housing cover.
2. Remove the tank housing cover (214).
3. Point the crimping head downward and remove the
oil plug (16). Add oil if necessary.
4. Replace the oil plug and the tank housing cover.
Secure with screws.
Recommended Hydraulic Oils
AVIA HVI 15
Shell Tellus T-15
Mobil DTE 11
NUTO H 15
GO
NO GO

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK06AT and EK06ATC
Troubleshooting
Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.
of tool.
Crimping tool battery contacts damaged. Reform contacts.
Tool components worn or damaged. Return tool to an authorized
Greenlee service center.
Ram does not advance com- Oil level is low. Check oil level. Refill reservoir.
pletely. Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately
10 seconds.
Battery load display flashes Battery charge low. Charge or replace battery.
constantly.
Tool loses oil. Damaged internal seal. Return tool to an authorized Greenlee
service center.
Oil plug not installed properly. Refill reservoir and replace plug.
PROBLEM PROBABLE CAUSE PROBABLE REMEDY
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 crimping tool.
3. Reinstall battery and check the tool again.