Greenlee GATOR EK22GL User manual

INSTRUCTION MANUAL
999 4521.5 © 2005 Greenlee Textron Inc. IM 1552 REV 8 5/05
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR®Plus
EK22GL
Battery-powered,
High-speed Crimping Tool
Serialnummer

EK22GL Battery-powered, High-speed Crimping Tool
Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
GATOR is a registered trademark 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
Identification ................................................................... 5
Specifications ................................................................. 5
Operation ................................................................... 6–7
Die Selection .................................................................. 8
Connector Selection ....................................................... 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 and aluminum cable with
KC22-type, KA22-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.

EK22GL Battery-powered, High-speed Crimping Tool
Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
IMPORTANT SAFETY INFORMATION
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
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.
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.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
flying debris or hydraulic oil.
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 combina-
tions. Improper combinations 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 could 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 could
result in severe injury or death.

EK22GL Battery-powered, High-speed Crimping Tool
Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
IMPORTANT SAFETY INFORMATION
Note: Keep all decals clean and legible, and replace
when necessary.
Inspect tool and dies 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 dispose of batteries in a fire. They will vent
fumes and may explode.
Failure to observe this warning could 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 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.
Keep hands away from the crimping
head when crimping.
Failure to observe this warning could
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 may result in
injury or property damage.

EK22GL Battery-powered, High-speed Crimping Tool
Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
IdentificationIdentification
Specifications
EK22GL
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
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/s2
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; 350 kcmil aluminum
Maximum Crimping Force................................................................55 kN (6.2 tons)
Average Crimps per Charge ........................................................ approximately 120
Battery
Charging Voltage ............................................................................................... 12 V
Charging Time ................................................................................................ 1 hour
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