Greenlee GATOR EK628 User manual

INSTRUCTION MANUAL
GATOR®EK628
Battery-powered
Crimping Tool
Read and understand all of the instructions
and safety information in this manual before
operating or servicing this tool.
52023597 REV 3 © 2008 Greenlee Textron Inc. 5/08
Serialnummer

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The EK628 Battery-powered Crimping Tool is a hand-
held, self-contained crimping tool with removable
crimping jaws.
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:
EK628 Battery-powered Crimping Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge at 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 is a registered trademark of Greenlee Textron Inc.
Blackburn is a registered trademark of Thomas & Betts.
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
Die Selection ............................................................. 8
Connector Selection.................................................. 8
Maintenance.............................................................. 9
Troubleshooting......................................................... 9
Illustrations ........................................................ 10–11
Parts List ................................................................. 12

EK628 Battery-powered 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 infor-
mation 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 near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning
could result in severe injury or
death.
Wear eye protection when operat-
ing or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying 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.
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 die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
The relief valve will sound to indicate a completed
crimp, and the ram will retract. 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.
•
•
Keep hands away from the crimp-
ing head when crimping.
Failure to observe this warning
could result in severe injury or
death.

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
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.
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 and dies before use. Replace any
worn or damaged parts. A damaged or improp-
erly assembled tool can break and strike nearby
personnel.
Failure to observe this warning could result in severe
injury or death.
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.
This tool may be used in damp or wet environ-
ments, however, we recommend air drying the
tool before use if it becomes soaked. Damage
may result when the tool is operated prior to
drying out 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.
•
•
•
•
IMPORTANT SAFETY INFORMATION

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
2
4
3
5
6
1
7
7
8
Specifications
Crimping Tool
Length..................................................................................................... 465 mm (18-1/4")
Width........................................................................................................... 60 mm (2-3/8")
Depth .......................................................................................................... 98 mm (3-7/8")
Mass/Weight (with battery) ............................................................................2.5 kg (5.5 lb)
Sound Level ........................................................................................ 75 dB (A) at 1 meter
Vibration............................................................................................................. < 2.5 m/s2
Hydraulic Oil ...........................................................................................Shell Tellus® T 15
Recommended Operating Temperature Range..........-15 °C (5 °F) through 50 °C (120 °F)
Crimping Capacities
Maximum Crimping Force ........................................................................ 53.4 kN (6 tons)
Average Crimping Time ......................................................................................4 seconds
Average Crimps per Charge ....................................................................approximately 70
Battery
Charging Voltage ........................................................................................................ 9.6 V
Charging Time...........................................................................................................45 min
1. Lock Pin
2. Crimping Jaws
3. Retract Button
4. Battery Lock
5. Battery Cartridge
6. Trigger
7. Crimping die release
8. LED Display
Identification

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Operation
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.
Wear eye protection when operat-
ing or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Keep hands away from the crimp-
ing head when crimping.
Failure to observe this warning
could result in severe injury or
death.
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.
This tool may be used in damp or wet environ-
ments, however, we recommend air drying the
tool before use if it becomes soaked. Damage
may result when the tool is operated prior to
drying out 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.
LED Display
This tool is equipped with a special circuit board
incorporating several important features to inform
the user about the current status of the unit. The LED
signals in the following cases:

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Operation (continued)
Installing Dies
1. Select the proper dies for the connector to be
crimped.
2. Install dies in jaws making certain that they are
properly secured by the spring-loaded detents.
Preparing Cable
Follow the lug manufacturer’s instructions for appro-
priate cable strip length.
Crimping Direction
First Compression
Crimping Direction
SIDE A
Crimping Direction
SIDE B
First Compression
SIDE A
First Compression
SIDE B
Crimping Procedure
1. Insert conductor into the connector and align the
tool and die on the connector. Start in the center
for splices and on the end, nearest the pad, for
terminals.
2. Activate the tool by pulling the trigger. Continue to
hold the trigger until the ram retracts. This is the
signal that the crimp is complete.
3. Continue crimping the connector until the correct
number of crimps has been completed. Work from
the center to the outer edges for splices, alternat-
ing sides if possible, for the best compression
connections.
An incomplete crimp can cause a re.
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, and the ram will retract. 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.
•
•

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Die Selection
Crimps made on copper cable with Greenlee KC22-type dies and the copper connectors listed here are cUL and
UL classied.
Crimps made on copper or aluminum cable with Greenlee KA22-type dies and the dual-rated aluminum
connectors listed here are cUL and UL classied.
Refer to “Connector Selection” below for brand names and model numbers of appropriate lugs as well as
crimping instructions.
Dies for Copper Connectors
Catalog
Number
UPC
Number
Cable
Size
Color
Code
KC22-8 03079 8 AWG Red
KC22-6 03080 6 AWG Blue
KC22-4 03081 4 AWG Gray
KC22-2 03082 2 AWG Brown
KC22-1 03083 1 AWG Green
KC22-1/0 03084 1/0 AWG Pink
KC22-2/0 03085 2/0 AWG Black
KC22-3/0 03086 3/0 AWG Orange
KC22-4/0 03087 4/0 AWG Purple
KC22-250 03088 250 kcmil Yellow
KC22-300 03089 300 kcmil White
KC22-350 03090 350 kcmil Red
KC22-400 03091 400 kcmil Blue
KC22-500 03092 500 kcmil Brown
KC22-600B 03094 600 kcmil Green
Dies for Dual-rated Aluminum Connectors
Catalog
Number
UPC
Number
Cable
Size
KA22-8 06744 8 AWG
KA22-6 06745 6 AWG
KA22-4 06746 4 AWG
KA22-2 06747 2 AWG
KA22-1 06749 1 AWG
KA22-1/0 06750 1/0 AWG
KA22-2/0 06751 2/0 AWG
KA22-3/0 06752 3/0 AWG
KA22-4/0 06753 4/0 AWG
KA22-250 06754 250 kcmil
KA22-300 06755 300 kcmil
KA22-350 06756 350 kcmil
Connector Selection
Tool Range: Copper — 8 AWG to 600 kcmil†; Dual-rated Aluminum — 8 AWG to 350 kcmil
When used with KC22-type dies, this tool is cUL and UL classied for use with the following connector brands:
Connector
Type
Barrel
Type Anderson Blackburn® FCI Burndy Ilsco Panduit T&B Penn- Union†
No. of
Crimps*
Copper
Splice
Short VHSS CSP YS-LsCT SCSS/SCS 54504–54518 BCU
A
Long VHS CU YSsCTL SCL/SCH 54804–54818 BBCU
Copper
Lugs
Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L
YA/YA-L-TC/YA-L-2TC CRA/CRB LCAS/LCA LCD
54104–54118
54204–54218 BLU
Long VHCL CTL-L/LCN YA-2N CRA-L/CRB-L
CRA-2L/CRB-2L LCB/LCC 54930BE–54918BE 54850BE–54876BE BBLU
When used with KA22-type dies, this tool is cUL and UL classied for use with the following connector brands:
Connector
Type
Barrel
Type Anderson Blackburn® FCI Burndy Ilsco Panduit** T&B Penn- Union
No. of
Crimps*
Dual-rated
Aluminum
Splice
– VACS ASP YS-A AS SA 60501–60565 PIK
B
Dual-rated
Aluminum
Lugs
– VACL ATL YA-A
YA-ATN
ACL/ACN
2ACL/2ACN LAA/LAB 60101–60166 60230–60267 BLUA
* Use the number of crimps listed in the last column instead of the number provided with the connector:
A — 8 to 1/0 AWG: 1 crimp
2/0 AWG to 600 kcmil: 2 crimps
B — 8 to 2 AWG: 2 crimps
1 to 3/0 AWG: 3 crimps
4/0 AWG to 350 kcmil: 4 crimps
** 6 AWG to 350 kcmil
† 500 kcmil maximum with Penn-Union connectors
s8 AWG to 350 kcmil with Burndy copper splices
95R7

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
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.
Dies stop during operation. Oil level is low. Return tool to an authorized
Greenlee service center.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approxi-
mately 10 seconds
LED display glows for
20 seconds.
Battery charge low. Charge or replace battery.
Tool loses oil. Damaged internal seal. Return tool to an authorized
Greenlee service center.
Maintenance
Each Operating Day
Before use:
1. Inspect dies 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.
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.
After use:
1. Wipe all tool surfaces clean with a damp cloth and
mild detergent.
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.
2. Fully retract the ram. Place the tool in the carrying
case. Store in a cool, dry place.
3. Charge the battery.
Monthly
1. Thoroughly clean all surfaces.
2. Oil the pin joints.
Annually or After 10,000 Crimps
Return the tool to an authorized Greenlee service
center for inspection.
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 crimping tool.
3. Reinstall the battery and check the tool again.

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
56
54
53
55 50
30 31
32
33
34 35
36 37
38
39
51
23
22
21
20
50
52
70
71
72
73
74
76
77
75
78
Motor Assembly
Pump Housing Unit, Relief Valve Unit,
and Piston Pump Assembly
1
11
68
62
67
63
9
64
65
60
60
61
66
61
10
12
8
7 6
13
Illustrations
Main

EK628 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
90
91
92
93
94
95
96
97
100
101
103
102
99
98
116
115
118
117
111
117
118
114
113
110
110
Illustrations
Ram Unit and Crimping Jaw Unit—D3

EK628 Battery-powered Crimping Tool
Parts List
1* 50120050 Bushing with seal...................................... 1
6 50019295 Screw........................................................ 1
7 50019287 Relief valve lever ....................................... 1
8 52026640 Switch....................................................... 1
9 52023617 Decal, specication .................................. 1
10 50019414 Decal, Greenlee GATOR ........................... 1
11 50019708 Decal, pinch hazard.................................. 1
12 50019422 Decal, Greenlee GATOR ........................... 1
13 50019430 Decal, warning.......................................... 1
50018990 Piston pump assembly (includes 20–23)
20 50019317 Piston pump ............................................. 1
21 50019015 Spring ....................................................... 1
22 50019309 Piston pump housing................................ 1
23* Piston seal ................................................ 1
50018922 Relief valve unit (includes 30–39)
30* Seal........................................................... 1
31 50019554 Valve seat.................................................. 1
32 50019465 Needle valve ............................................. 1
33 50019546 Plunger ..................................................... 1
34 50103776 Spring ....................................................... 1
35 50070150 Lock washer ............................................. 2
36* O-ring........................................................ 1
37* O-ring........................................................ 1
38 50019520 Pressure relief ........................................... 1
39 50109146 Screw........................................................ 1
50032399 Pump housing unit (includes 50–56)
50* 50019724 Clamp ....................................................... 2
51* 50019023 Screw........................................................ 1
52 50109162 Threaded bushing..................................... 1
53 50032445 Pump block .............................................. 1
54 50109308 Threaded bushing..................................... 1
55 50109316 Screen....................................................... 1
56 50019449 Reservoir................................................... 1
50109430 Housing unit, green (includes 60–68)
60 50042076 Screw........................................................ 4
61 50019767 Screw........................................................ 2
62 50043960 Compression spring, DA5.5 x L14.0)........ 1
63 50019341 Trigger link ................................................ 1
64 Battery release lever ................................. 1
65 Housing half.............................................. 1
66 Housing half.............................................. 1
67 Button, relief valve .................................... 1
68 Cover, trigger ............................................ 1
50018957 Motor assembly (includes 70–78)
70 50019651 Retaining ring............................................ 1
71 50019589 Pin............................................................. 1
72 50019619 Motor cap ................................................. 1
73 50019538 Disc housing ............................................. 1
74 50019627 Disc........................................................... 2
75 Screw........................................................ 2
76 Gear lube, 1.5 g ........................................ 1
77 Motor adapter........................................... 1
78 Motor, electric........................................... 1
Key Part No. Description Qty Key Part No. Description Qty
50032410 Ram unit (includes 90–103)
90 50032542 Sheath ...................................................... 1
91 50032550 Shoulder bolt ............................................ 1
92 50032569 Disc........................................................... 1
93 50032585 Compression spring ................................. 1
94 50032623 Washer...................................................... 1
95* O-ring........................................................ 1
96 50019295 Screw........................................................ 1
97 50032631 Ram housing............................................. 1
98 50032640 Compression spring ................................. 1
99 50032658 Locking pin ............................................... 1
100 50032666 Compression spring ................................. 1
101 50032674 Pin............................................................. 1
102 50032682 Roller......................................................... 2
103 50032690 Ram .......................................................... 1
52024683 Crimping jaw unit, CJ22 (includes 110–118)
110 Jaw, CJ22 ................................................ 2
111 52022544 Spring ....................................................... 1
113 50032275 Retaining ring............................................ 2
114 50032500 Pin pivot.................................................... 1
52023623 Die retaining pin kit (includes 115–118)
115 Die retaining pin........................................ 2
116 Compression spring ................................. 2
117 Release button.......................................... 2
118 Retaining ring............................................ 2
* 50047957 Seal kit (includes items marked
with an asterisk)
52027056 Carrying case
50035444 Decal, case
52026638 9.6 V battery
50021788 12 V charger 110 VAC
52023076 12 V charger 12 VDC
50021800 12 V charger 220 VAC
Accessory Crimping Jaw Units
52025123 CJD3BG for use with W- and X-type
crimping dies
52025126 CJD3O for use with W- and X-type
crimping dies
52024068 CJD3 for use with W- and X-type
crimping dies
04829 CJK for use with Thomas & Betts
“6TON” crimping dies
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