Greenlee GATOR EK12ID User manual

INSTRUCTION MANUAL
GATOR®EK12ID
Battery-powered,
Dieless Crimping Tool
with Retraction Stop
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
52031418 © 2007 Greenlee Textron Inc. 9/07
Serialnummer

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The EK12ID Battery-powered, High-speed Crimping
Tool is a hand-held, self-contained, dieless crimping tool
intended to crimp aluminum and copper connectors
onto electrical cable.
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.
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:
EK12ID11 Battery-powered, Dieless Crimping Tool
with 120 volt charger
EK12ID12 Battery-powered, Dieless Crimping Tool
with 12 volt charger
EK12ID22 Battery-powered, Dieless Crimping Tool
with 230 volt charger
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 Greenlee
Textron Inc.
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
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
Important Safety Information ......................................3-4
Identication................................................................... 5
Specications................................................................. 5
Operation.....................................................................6-7
Connector Selection....................................................... 8
Maintenance................................................................... 9
Periodic Pressure Relief Valve Check........................9-10
Troubleshooting............................................................ 11
Disassembly ................................................................. 12
Assembly...................................................................... 13
Head and Indenter Replacement ................................. 14
Illustrations ..............................................................15-17
Parts List .................................................................18-20

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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.
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 electri-
cal lines, use proper personal protec-
tive 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.
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.
•
•
Do not use solvents or ammable
liquids to clean the crimping tool.
Solvents or ammable liquids could
ignite and cause serious injury or
property damage.
An incomplete crimp can cause a re.
Use proper connector and cable combinations.
Improper combinations can result in an incomplete
crimp.
The relief valve will sound and the crimping tool
automatically retracts when a complete crimp has
been achieved. If you do not hear a “pop” and the
crimping tool does not automatically retract, the
crimp is not complete.
Failure to observe these warnings could result in
severe injury or death.
•
•
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
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.
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 could 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.
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 environ-
ments; 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 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 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.

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Specifications
Crimping Tool
Length ...........................................................................................426.7 mm (16.8")
Width.................................................................................................94.0 mm (3.7")
Height (with battery) ......................................................................315.0 mm (12.4")
Mass/Weight (with battery)................................................................6.7 kg (14.8 lb)
Sound Level .............................................................................. 75 dB (A) at 1 meter
Vibration .................................................................................................... < 2.5 m/s2
Motor Type .......................................................................DC permanent eld motor
Motor Voltage................................................................................................ 12 VDC
Hydraulic Oil....................................................190 ml (0.4 pint) of Shell Tellus®T 15
Recommended Operating Temperature Range.............–15 °C to 50 °C (5 °F to 120 °F)
Crimping Capacities
Crimping Range
Aluminum.......................................................................... #6 AWG to 1000 kcmil
Copper.............................................................................. #4 AWG to 1000 kcmil
Battery
Charging Voltage........................................................................................... 12 VDC
Charging Time................................................................................................. 1 hour
1. Trigger
2. Retract Button
3. Battery Load Display
4. Battery
5. Head
6. Latch (for opening head)
7. Indenter
8. Housing
9. Reservoir Cover
10. Lanyard Ring
1
2
3
4
5
6
78
9
10

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Operation
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 could result in severe
injury or death.
Electric shock hazard:
This tool is not insulated. When using
this unit on or near energized electri-
cal lines, use proper personal protec-
tive 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:
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.
An incomplete crimp can cause a re.
Use proper connector and cable combinations.
Improper combinations can result in an incomplete
crimp.
The relief valve will sound and the crimping tool
automatically retracts when a complete crimp has
been achieved. If you do not hear a “pop” and the
crimping tool does not automatically retract, the
crimp is not complete.
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 environ-
ments; 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.
•
•
•
•
Charging the Battery
Read the instructions supplied with the battery charger.
Battery Condition
For a cUL or UL classied crimp, see the connector
table in this instruction manual.
Preparation
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.
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

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Operation (cont’d)
Crimping
1. Insert the cable fully into the connector.
2. Place the connector into the V of the crimping head,
as shown below.
Connector
3. If open, close the crimping head. Make sure the
head and latch are fully engaged.
4. For a UL or cUL classied crimp, complete the
number of crimps specied in the connector chart
(shown on page 8).
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 connec-
tor 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.

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
cUL and UL Classified Crimps
Crimps made with the Greenlee EK12ID Dieless 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 Connector
Table for the brand names and model numbers of appropriate connectors and the number of crimps required.
Connector Table
(NOT for use with flex, navy or welding wire)
Copper Connector Type Anderson Blackburn®FCI Burndy Ilsco Panduit T & B Penn-Union Tyco (AMP)
Copper Splices VHSS CSP YS-L CT SCSS 54506 to 54528 BCU —
VHS CU YS CTL SCS 54806 to 54828 BBCU
SCL, SCH
Copper Lugs VHCS CTL YA, YA-L, YA-2L CRA, CRB, CRC LCAS 54106 to 54128 BLU 1099898-2 to 1-1099898-5
VHCL CTL-L YA-2LN, YA-2N CRA-L, CRB-L LCA 54206 to 54228 BBLU 1099899-2 to 1-1099899-9
LCN YA-L-TC, YA-L-2TC CRA-2L LCB 54906BE to 54928BE 1099939-1 to 1-1099939-5
YA-2TC, YAZ CRB-2L LCD, LCC 54854BE to 54882BE
YAZ-2N, YAZ-2TC CRC-2L LCAN
1 1 1 1 1 1 1 1
Aluminum Connector Type Anderson Blackburn®FCI Burndy Ilsco Panduit T & B Penn-Union
Dual-Rated Aluminum Splices VACS ASP YS-A AS SA 60507 to 60584
Dual-Rated Aluminum Lugs VACL ATL YA-A ACL, ACN LAA 60106 to 60184 BLUA
YA-A-TN 2ACL, 2ACN LAB 60230 to 60284
1 1 1 1 1 1 1
2 1 1 1 2 1 1
2 2 2 2 2 2 2
* When crimping with the EK12ID Crimping Tool, use the number of crimps listed in this table instead of the number provided with the connector.
* Number
of Crimps
* Number
of Crimps
Cable Size: #6 AWG - 500 kcmil
Cable Size: 600 kcmil - 800 kcmil
Cable Size: 1000 kcmil
Copper Cable Size:
#4 AWG - 1000 kcmil
PIK
BCUA

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Maintenance
Wear eye protection when operating
this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
Each Operating Day
Before use:
1. Inspect indenter and head for wear or damage such
as cracks, gouges, or chips.
2. Inspect the tool for damage or leaks. If damage is
detected, return the tool to an authorized Greenlee
service center for inspection.
High pressure hazard:
Do not use ngers or hands to check
for oil leaks. High pressure
oil easily punctures skin causing
serious injury, gangrene, or death.
If injured, seek medical help immedi-
ately to remove oil.
After use:
1. Wipe all tool surfaces clean with a damp cloth and
mild detergent.
Do not use solvents or ammable
cleaners to clean the tool body.
Solvents could ignite, causing serious
injury or property damage.
2. Place 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.
3. Oil the pin joints, and metal surfaces that slide.
Annually or After 10,000 Cycles
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 holding the tank housing cover.
2. Remove the tank housing cover.
3. Point the head towards the ground and remove the
oil plug. 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 11M
NUTO®H 15
Periodic Pressure Relief Valve Check
Pinch points:
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning could
result in severe injury or death.
The crimping tool’s relief valve may require occasional
adjustment. To determine whether this adjustment is
necessary, periodically test the crimping tool with a
Greenlee 50013408 Test Meter, 50065750 Sensor
and 52024054 Adapter (purchased separately).
1. Install the Greenlee 50065750 Sensor into Adapter
52024054, as shown below.
52024054
Adapter
50065750
Sensor

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Periodic Pressure Relief Valve Check (cont’d)
2. Lift the latch to open the crimping head and install
the Adapter between the Indenter and Crimp Head.
Locate the round end of the Adapter against the
Indenter and close the Crimp Head against the
V-surfaces on the Adapter, as shown below.
Check that the head and latch are fully engaged.
3. Connect the Sensor cable to the test meter and cali-
brate the sensor per operating instructions provided
with the 50013408 Test Meter.
4. Press the crimping tool trigger to advance the
indenter until the pressure relief valve activates.
The display on the test meter should show a force
of 107.8 to 110.8 kN (24,250 to 24,925 lb). If
the force reading is outside this range, send the
crimping tool to an authorized service center for
adjustment.
Relief valve adjustments must be done by an
authorized service center.

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Troubleshooting
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 Probable Cause Probable Remedy
Tool is inoperative. Dirt, contaminants, etc., in ram area
of tool.
Clean tool.
Crimping tool battery contacts
damaged.
Reform contacts.
Tool components worn or damaged. Return tool to an authorized
Greenlee service center.
Indenter does not advance
completely.
Oil level is low. Check oil level. Rell reservoir.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approxi-
mately 10 seconds.
Battery load display ashes
constantly.
Battery charge low. Charge or replace battery.
Tool loses oil. Damaged internal seal. Return tool to an authorized
Greenlee service center.
Oil plug not installed properly. Rell reservoir and replace plug.

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
12
Disassembly
Main Components
1. Remove the battery.
2. Remove the screw (17) and stop (18).
3. Unscrew and remove the crimp head assembly.
4. Remove the piston (16). Replace the piston O-ring
(14) and piston backup ring (15).
5. Unscrew two tank cover screws (53) and remove
the tank cover (58).
6. Remove the hydraulic reservoir plug (76) and drain
the hydraulic uid.
7. Reinstall the plug.
8. Remove the remaining housing screws (51 and 53).
9. Remove the right housing half (59).
10. Remove the switch cover (56).
11. Lift the pump/motor assembly and circuit board
from the left housing half (60). Lift the LED from its
housing (61).
12. Slide a plastic bag over the circuit board and
electronic subassemblies. Tape the bag shut to
protect the subassemblies from hydraulic oil and
other contamination.
13. Unscrew the shoulder bolt (117) and remove the
release lever (116).
14. Remove screws (108) and separate the gear
housing/motor subassembly from the pump
housing.
Pump
1. Use a hooked tool to remove the reservoir O-ring
(80). Gently tug it over the reservoir.
2. Remove the reservoir (74).
3. Remove the pump piston (152).
4. Remove the screw plug (151), piston seal (153),
pump piston (150), valve stem (156), and spring
(155). Replace the sealing washer (154).
5. Use a piece of tape to mark the side of the relief
that is facing up. (This is a reference point for
reassembly.) Remove the unloading valve by
unscrewing the adjusting nut (126).
6. Remove the feeder tube subassembly by unscrew-
ing the feeder tube (78). Replace the oil lter (77).
Remove metal chips from the magnet (82).
7. Remove the threaded bushing (72) and replace
the O-ring (73).
Motor, Gearbox, and Bearing
1. Remove the tamper-proof paper seal (96).
2. Remove two screws (92). Remove the end cap (102).
3. Apply pressure evenly at three points around the
ball bearing (91) and gently pry the bearing up to
remove it.
4. Remove the eccentric (103), grooved ball bearing
(101), and snap ring (100) subassembly from the
shaft.
5. Remove four screws (93). Remove the mounting
block (109) from the gear housing (94).
6. Use a snap-ring removal tool to remove the snap
ring (100).
7. Unscrew four bolts (not numbered) from the gear
housing (94). Separate the gear housing from
ange (110). Unscrew two Fillister head screws (112)
to separate the ange from the motor (90).

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
Assembly
Motor, Gearbox, and Bearing
1. Install two Fillister head screws (112) into the ange
(110) and motor (90). Tighten the screws.
2. Install four screws (not numbered) into the gear
housing (94). Tighten the screws.
3. Install four screws (93) into the mounting block (109)
and gear housing (94). Tighten the screws.
4. Replace the grooved ball bearing (101) and snap
ring (100) subassembly.
5. Replace the eccentric (103). Use a ber mallet to
tap the eccentric onto the shaft. Replace the ball
bearing (91).
6. Align the end cap (102). Use a ber mallet to tap the
cover until it is ush on the mounting block (109).
Install two screws (92).
7. Align the gear housing/motor subassembly so that
the pump piston (152) extends through the mount-
ing block (109) and makes contact with the grooved
bearing (101). Locate and start the screws (108)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert the pump piston (152) into the pump housing.
2. Insert the seal (122) and unloading valve assembly
into the pump housing. Grasp the needle valve
subassembly by the pressure relief (126) and twist
it several turns clockwise. Stop when the piece of
tape is facing up.
3. Assemble the pump piston (150), valve stem (156),
piston seal (153), spring (155), and screw plug (151).
Be sure to replace the sealing washer (154). Torque
the screw plug (151) to 102 Nm (75 ft-lb).
4. Install the release lever (116) so that the forked end
engages the unloading valve subassembly between
the adjusting nut (126) and the support ring (127).
Install the screw (117).
5. Insert the threaded bushing (79) and feed tube
subassembly (77, 78, 82). Screw in until snug.
6. Install the reservoir (74). Slip the O-ring (80) over
the reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing.
7. Insert the plug (76) into the reservoir.
Main Components
1. Remove the protective plastic bag from the
electronics subassembly. Insert the LED into the
LED bushing (61).
2. Lay the gear housing/motor subassembly into the
left half of the housing. Insert the circuit board into
the circuit board slot so that the wires and chip face
in the direction of the trigger.
3. Lay the wires into the case. Be sure that the wires
will not be pinched.
4. Guide the wires for the battery clip so that the
battery wires lay on top of the electronics box;
install the battery clip so the red wire is upward.
5. Install the trigger cover (56). Press and release the
trigger to be sure that it operates freely.
6. Locate the right housing half (59) on top of the left
housing half (60). Check for pinched wires.
7. Install the housing screws (51 and 53).
Note: The handle screw (51) must engage the
nut (52).
8. Install the retraction stop valve body (12) with
O-rings (5 & 6) and screw (13). Install the retraction
stop spring assembly (17) and screw (18).
9. Install the piston (16).
10. Replace the crimp head assembly. Twist yoke (20)
until it stops; back off 3/4 of a turn. Install the stop
(18) and screw (17). Be sure that the crimp ing head
assembly rotates freely approximately 350°.
11. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the ll plug
(76) and ll the reservoir with hydraulic oil.
12. Install the battery.
13. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir with hydraulic
oil. Replace the ll plug (76).
14. Replace the tank cover (58) and tank cover
screws (53).

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
14
Indenter
1. Lift the latch and open the crimping head.
2. Remove set screw (28), indenter (25), and any
spacers (23 and 24).
3. Lubricate indenter tangs that slide against the yoke.
Reinstall spacers (23 and 24) and indenter (25).
4. Close crimping head and check that latch and head
are fully engaged.
5. Reinstall the battery and advance the indenter to
full stoke. Release trigger when the sound of motor
speed begins to slow down.
6. Measure the distance between the bottom of the
indenter and head as shown below. The distance
should measure 4.953 mm to 5.207 mm (.195" to
205"). If the dimension is outside this range, remove
set screw (28) and indenter (25).
to increase distance, remove a spacer (23, 24).
to decrease distance, add a spacer (23, 24).
.205
.195
7. Install indenter (25) and secure with set screw (28).
•
•
Head
1. Lift the latch and open the crimping head.
2. Remove the retaining ring (26), pin (27), head (29),
and spring (31).
3. Install spring (31) with long end into the yoke hole.
Reinstall head (29), pin (27), and retaining ring (26).
4. Close crimping head and check that latch and head
are fully engaged.
5. Reinstall the battery and advance the indenter to
full stoke. Release trigger when the sound of motor
speed begins to slow down.
6. Measure the distance between the bottom of the
indenter and head as shown below. The distance
should measure 4.953 mm to 5.207 mm (.195" to
205"). If the dimension is outside this range, remove
set screw (28) and indenter (25).
to increase distance, remove a spacer (23, 24).
to decrease distance, add a spacer (23, 24).
.205
.195
7. Install indenter (25) and secure with set screw (28).
•
•
Indenter and Head Replacement
This procedure is separated into two sections, one for the indenter and one for the head.

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
15
Illustration—Housing Unit
4
57
51
56
53 7
10
53
59
52
61
60
9
11
58
53
14
15
16
13
17
18
12
56

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
16
Illustration—Crimp Head
29
25
22
27
27
30
26
20
26
31
26
24 23
28
31
34
35
36
26
21
32
33

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
17
Illustration—Pump Housing, Reservoir Assembly, and Motor Assembly
121
80
140
141
72 73
83
79
84
70
71
76
74
82
85
77
78
92
91
101
93
109
117
112
90
110
100
102
103
96
108
116
94
155 156 150 153
152
151
154
128
129
122 123
124
120
130 125
126
127
118

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
18
Parts List
Key Part No. Description Qty
52031380 Retraction stop valve (includes 5, 6, 12, 13, 17, 18)
5* O-ring ........................................................................................................ 1
6* O-ring ........................................................................................................ 1
7 50067753 Circuit board, programmed....................................................................... 1
9 52020514 Decal, identication................................................................................... 1
10 52020515 Decal, warning .......................................................................................... 1
11 50062140 Decal, pinch hazard .................................................................................. 1
12 Retraction stop valve body ....................................................................... 1
13 Screw, at head socket............................................................................. 1
14* 50067770 O-ring ........................................................................................................ 1
15* 50067761 Backup ring............................................................................................... 1
16 50067796 Piston ........................................................................................................ 1
17 Retraction stop spring assembly .............................................................. 1
18 Screw, socket head cap............................................................................ 1
20 52020271 Yoke .......................................................................................................... 1
21* O-ring ........................................................................................................ 1
22 52020510 Ram........................................................................................................... 1
23 52020512 Spacer, .010 x 1.181 x .531 ......................................................(as needed)
24 50337300 Spacer, .025 x .997 x .549 ........................................................(as needed)
25 52020277 Indenter..................................................................................................... 1
26 90513533 Retaining ring ............................................................................................ 4
27 52020513 Pin, pivot ................................................................................................... 2
28 90523385 Screw, #10-32 x .25 socket set ................................................................ 1
29 52020275 Head, crimp .............................................................................................. 1
30 52020273 Latch ......................................................................................................... 1
31 50111230 Spring, torsion........................................................................................... 2
52021550 Spring Kit (includes 21, 32-36)
32 Spring........................................................................................................ 1
33 50066897 Screw, M6 x 80 mm socket head cap ...................................................... 1
34 End cap..................................................................................................... 1
35 50043676 Screw, M5 x 10 ......................................................................................... 1
36 50066943 Stop........................................................................................................... 1
52020936 Housing unit (includes 51–61)
51 50042203 Screw ................................................................................................... 1
52 50042211 Nut........................................................................................................ 1
53 50042076 Screw ................................................................................................. 12
56 Switch cover (black) ............................................................................. 1
57 Trigger guard ........................................................................................ 1
58 Reservoir cover .................................................................................... 1
59 Housing, right side ............................................................................... 1
60 Housing, left side ................................................................................. 1
61 50042416 Bushing LED......................................................................................... 1

EK12ID Battery-powered, Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
19
Parts List (cont’d)
52020937 Pump housing, reservoir assembly (includes 70–83)
◊70 Ring tie ................................................................................................. 1
◊71 Cable tie ............................................................................................... 1
72 50041444 Threaded bushing ................................................................................ 1
73* O-ring ................................................................................................... 1
◊74 Hydraulic reservoir ............................................................................... 1
◊76 Reservoir plug ...................................................................................... 1
77* Filter ..................................................................................................... 1
78 50058827 Filter adapter ........................................................................................ 1
79 50058851 Threaded bushing ................................................................................ 1
◊80* O-ring ................................................................................................... 1
82* Magnet ................................................................................................. 1
83 Pump housing ...................................................................................... 1
84 50058290 Attachment ring.................................................................................... 1
85 50041983 Ring ...................................................................................................... 1
50121758 Motor assembly (includes 90–113)
n 90 52024659 Motor and pinion.................................................................................. 1
o l 91 Ball bearing .......................................................................................... 1
o 92 Screw ................................................................................................... 2
o 93 Screw ................................................................................................... 4
n 94 Gearbox................................................................................................ 1
o 96* Self Adhesive Label.............................................................................. 1
o l 100 Retaining ring ....................................................................................... 1
o l 101 Grooved ball bearing............................................................................ 1
o 102 End cap ................................................................................................ 1
o l 103 Eccentric .............................................................................................. 1
o 108 Screw ................................................................................................... 2
o 109 Eccentric case...................................................................................... 1
n 110 Flange................................................................................................... 1
n 112 Screw ................................................................................................... 2
113 52028323 Screw, gear box ................................................................................... 4
50118927 Release lever assembly (includes 116-118)
116 Release lever........................................................................................ 1
117 Screw, socket head.............................................................................. 1
118 Compression spring ............................................................................. 1
52031134 Relief valve assembly (includes 120–130)
120* Washer ................................................................................................. 2
121* O-ring ................................................................................................... 1
122* Seal ...................................................................................................... 1
123 50053630 Valve seat ............................................................................................. 1
124 Plunger ................................................................................................. 1
125* O-ring ................................................................................................... 1
126 Adjusting nut ........................................................................................ 1
127 Support ring ......................................................................................... 1
128* Retaining ring ....................................................................................... 1
129 Needle valve......................................................................................... 1
130 Spring................................................................................................... 1
Key Part No. Description Qty

EK12ID Battery-powered, Dieless Crimping Tool
USA 800-435-0786 Fax: [phone]
815-397-7070 Fax: [phone]
Canada 800-435-0786 Fax: [phone]
International [phone] Fax: [phone]
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 Printed in USA
50013475 Electrical assembly (includes 140–144)
140 50041266 Switch .................................................................................................. 1
141 50041274 Battery contacts ................................................................................... 1
142 50063383 Circuit board, unprogrammed.............................................................. 1
143 Wire (not shown)................................................................................... 1
144 Wire (not shown)................................................................................... 1
50013483 Piston pump assembly (includes 150–156)
150 Pump piston ......................................................................................... 1
151 Screw plug ........................................................................................... 1
152 Pump piston ......................................................................................... 1
153* Piston seal............................................................................................ 1
154* Sealing washer ..................................................................................... 1
155 Spring................................................................................................... 1
156 Valve stem ............................................................................................ 1
Accessories (not shown):
50013408 TC1S KIT Test Meter Kit
50065750 TF130 Sensor, load for 130 kN (29,225 lb)
52024054 MA12ID Adapter unit
Repair Parts:
* 50014099 Seal kit (includes items marked with *)
52020516 Decal, connector chart (case lid liner)
52020939 Case with inserts
50070630 12 V battery NiMH
50030469 12 V charger 110 VAC
50030477 12 V charger 220 VAC
50030485 12 V charger 12 VDC
◊ 52031419 Reservoir kit, 200 ml (includes 70, 71, 74, 76 & 80)
n 52028329 Motor and gear box assembly
l52028331 Eccentric bearing kit
o 52028332 Eccentric kit
Key Part No. Description Qty
Parts List (cont’d)