Greenlee GATOR EK1240K User manual

999 3201.6 © 2001 Greenlee Textron IM 1383 REV 4 8/01
GATOR®EK1240K and EK1240KC
Battery-powered Crimping Tool
with Two-speed Ram
INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
KEEPTHIS MANUAL
Table of Contents
Description .....................................................................2
Purpose..........................................................................2
Important Safety Information ......................................3-4
Identification...................................................................5
Location of Decals .........................................................6
Specifications.................................................................6
Operation ....................................................................7-8
Maintenance ..................................................................9
Troubleshooting ...........................................................10
Disassembly/Reassembly.......................................11-12
Service .........................................................................13
Exploded Views ......................................................14-16
Parts List .................................................................17-19
Description
The EK1240K Hydraulic Crimping Tool is a hand-held,
self-contained, battery-powered tool intended to crimp
aluminum and copper connectors onto electrical cable.
The EK1240K accepts Kearney-style dies for crimping
various types of connectors onto #8 to 750 MCM wire.
The EK1240KC has a PVC-covered crimping head.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction 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
This instruction manual is intended to familiarize opera-
tors and maintenance personnel with the safe operation,
troubleshooting and repair procedures for the Greenlee
EK1240K and EK1240KC.
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 improve-
ments 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.
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.

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
IMPORTANT SAFETY INFORMATION
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 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:
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 can
result in serious injury, gangrene 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.
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
cleaners to clean the tool body.
Solvents could ignite, causing
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 incom-
plete crimp.
• An audible “pop” indicates that the crimping tool
has achieved a complete crimp. If you do not
hear a “pop” the crimp is incomplete.
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.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
IMPORTANT SAFETY INFORMATION
Note: Keep decals clean and legible. Replace decals
when necessary.
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 operate tool without dies. Damage to the
ram or crimping head may result.
• Do not use this tool for continuous use. After
30 – 40 crimping cycles, allow the tool to cool for
15 minutes.
• Do not secure this tool in a vise. A vise can
damage the housing.
• Protect the tool from moisture. Any moisture
inside the housing can damage internal circuitry.
• Use this tool for the manufacturer’s intended use
only.
Failure to observe these precautions can 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 can result in
injury and property damage.
Do not dispose of batteries in a fire. They will vent
fumes and may explode.
Failure to observe this warning can result in
severe injury from harmful fumes or burns from
flying debris.
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 can 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 can result in
injury or property damage.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
Identification
EK1240K and EK1240KC
1. Housing 5. Trigger Lock Button
2. Retract Button 6. Trigger
3. Battery 7. Battery Load Display
4. Hand Guard 8. Die Release Set Screw
8
1
2
7
4
6
5
3

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
Location of Decals
Specifications
Crimping Tool
Length.....................................................................................396 mm (15.59")
Width ..........................................................................................80 mm (3.16")
Height .....................................................................................306 mm (12.03")
Mass/Weight (with Battery) ...................................................... 6.9 kg (15.2 lb)
Sound Level .....................................................................75 dB (A) at 1 meter
Vibration ........................................................................................... < 2.5 m/s2
Motor Voltage .......................................................................................12 VDC
Hydraulic Oil ............................................50 ml (0.1 pint) of Shell Tellus®T 15
Crimping Capacities
Crimping Range ...................................10 mm2to 400 mm2(#8 to 750 MCM)
Crimping Force.......................................................................106 kN (12 tons)
Battery
Charging Voltage..................................................................................12 VDC
Charging Time........................................................................................ 1 hour
500 6214.0
500 6509.2 (EK1240K)
500 7231.5 (EK1240KC)
(opposite side)
500 6506.8 (EK1240K)
500 7228.5 (EK1240KC)

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
Operation
Electric shock hazard:
This tool is not insulated. When
using this tool on or 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
this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris or hydraulic oil.
An incomplete crimp can cause a fire. Use proper
die, connector and cable combinations.
• Improper combinations can result in an incom-
plete crimp.
• An audible “pop” indicates that the crimping tool
has achieved a complete crimp. If you do not
hear a “pop” the crimp is incomplete.
Failure to observe these warnings can result in
severe injury or death.
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 can
result in serious injury, gangrene or
death.
• Keep hands away from the
crimping tool head when crimping.
• Lock trigger when not in use.

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
CRIMPING DIRECTION
1ST COMPRESSION
CRIMPING DIRECTION
SIDE A
CRIMPING DIRECTION
SIDE B
1ST COMPRESSION
SIDE A
1ST COMPRESSION
SIDE B
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. Clean the die seat area.
2. Install the proper size and type of crimping dies.
3. Insert one of the die halves into the ram by pressing
the die stem into the hole located in the ram.
4. Insert the other die half into the C-head by pressing
the die stem into the hole located in the C-head.
The die half can then be locked in place by tighten-
ing the lock screw.
5. Follow the connector manufacturer’s instructions
for appropriate cable strip length and surface
preparation.
6. Insert cable fully into connector and center the
connector between the dies.
7. Press the trigger lock button to release the trigger.
8. Using the sequence illustrated here, press the
trigger to advance the dies. Continue to crimp until
the pressure relief valve activates.
Note: Pressure relief occurs at approximately
106 kN (12 tons) and is indicated by
an audible “pop.”
9. After achieving pressure relief, the ram will auto-
matically return to the start position and the dies will
retract.
10. Complete the number of crimps specified by the
connector manufacturer.
11. Remove connector from crimper.
Note: After completing the last crimp on an
aluminum connector, wipe off the excess
oxide inhibitor.
Operation (cont’d)

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
Maintenance
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 can
result in serious injury, gangrene 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.
Daily
Before use:
1. Inspect dies for wear or damage, such as cracks,
gouges or chips.
2. Inspect the crimping tool for damage or leaks.
After use:
1. Use a damp cloth and mild detergent to clean the
housing. Allow housing to dry.
2. Fully retract the ram and lock the trigger. Place the
crimping tool in the carrying case and store in a
cool, dry place.
3. If necessary, recharge the batteries – see the
instructions supplied with the battery charger.
Monthly
1. Thoroughly clean all surfaces.
2. Check the oil level.
Annually or After 10,000 Crimps
1. Replace the hydraulic oil.
2. Send the tool to an authorized Greenlee service
center for inspection.
Checking the Oil Level
1. Remove the two screws that retain the tank housing
cover. Remove the tank housing cover.
2. Point the crimping head downward and remove the
oil reservoir plug. Fill reservoir if necessary.
3. Replace the oil plug and tank housing cover.
Recommended Hydraulic Oils
AVIA®HVI 15
Shell Tellus T 15
Mobil®DTE 15
NUTO®H 15
Do not use solvents or flammable
cleaners to clean the tool body.
Solvents could ignite, causing
serious injury or property damage.
Pinch points.
Keep hands away from the crimping
tool head when crimping.
Relief valve adjustments must be done by an
authorized service center.

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
EK1240K and EK1240KC
Troubleshooting
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
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.
Dead battery. Charge or replace.
Dies stop during operation. Oil level is low. Check oil level. Refill reservoir.
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.
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.