Greenlee GATOR PRO E12CCX User manual

INSTRUCTION MANUAL
GATOR®PRO E12CCX
12-ton Battery-powered,
High-speed Tool
with Retraction Stop
Read and understand all of the instructions and
safety information in this manual before operating
of servicing this tool.
Register this product at www.greenlee.com
52031420 REV 1 © 2010 Greenlee Textron Inc. 9/10
Serial Code AKK

E12CCX 12-ton Battery-powered, High-speed Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The E12CCX 12-ton Battery-powered, High-speed Tool
is a hand-held, self-contained tool intended to crimp
cable, cut cable and threaded rod, and punch holes with
the proper adapters.
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:
E12CCX 12-ton Battery-powered,
High-speed 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 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..................................................................6–13
Crimping .................................................................6–7
Cutting ....................................................................... 8
Punching...............................................................9–13
U-type Crimping Dies for Copper Connectors............ 14
Connector Selection ................................................ 14
U-type Crimping Dies for Aluminum Connectors........ 14
Additional U-type Dies ................................................ 15
Available Accessories.................................................. 15
Maintenance................................................................ 16
Periodic Pressure Relief Valve Check.......................... 16
Troubleshooting........................................................... 17
Disassembly ................................................................ 18
Assembly..................................................................... 19
Illustrations .............................................................20–23
Parts List ................................................................24–26

E12CCX 12-ton Battery-powered, High-speed 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 pre-
venting 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:
Do not use hands to check for oil
leaks. Oil under pressure easily punc-
tures skin. If injured, seek medical
attention immediately to remove oil.
Failure to observe this warning could
result in serious injury, gangrene, or
death.
Do not use solvents or ammable
liquids to clean the tool body.
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 combinations.
Mismatched combinations can result in an incom-
plete crimp.
• The crimping tool automatically retracts when a
complete crimp has been achieved. If you do not
hear a “pop,” the crimp is incomplete.
Failure to observe this warning could result in severe
injury or death.
Pinch points:
• Remove battery before changing
dies, adapters, or jaws.
• Keep hands away from the crimp-
ing tool head when crimping.
Failure to observe these warnings
could result in severe injury or death.

E12CCX 12-ton Battery-powered, High-speed Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
IMPORTANT SAFETY INFORMATION
Do not dispose of the battery in a re. The battery will
vent fumes and it could explode.
Failure to observe this warning could result in severe
injury from harmful fumes or burns from ying debris.
Inspect tool, dies, and adapters 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 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, 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.
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 bat-
teries 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.

E12CCX 12-ton Battery-powered, High-speed Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Specifications
Tool
Overall Length .................................. 371 mm (14-5/8")
Width..................................................... 95 mm (3-3/4")
Height ......................................................330 mm (13")
Mass/Weight (with battery)..................6.5 kg (14.35 lb)
Force...................................................106 kN (12 tons)
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 ........ 50 ml (0.1 pint) of Shell Tellus®T 15
Recommended Operating
Temperature Range .............................. –15 °C to 50 °
(5 °F to 120 °F)
Battery
Charging Voltage .............................................. 12 VDC
Charging Time .................................................... 1 hour
1. Head
2. Latch (for opening head)
3. Housing
4. Retract Button
5. Battery Load Display
6. Battery
7. Trigger
8. Adapter Release Buttons
Crimping Capacities
Copper Color-Coded Lugs and Splices........750 kcmil
Aluminum Color-Coded Lugs and Splices ...750 kcmil
5/8" Service Entrance Connectors...........10–1/0 AWG
.840 Service Entrance Connectors .........1/0–4/0 AWG
Aluminum Overhead “H” Taps .........6 AWG–500 kcmil
One-Piece ACSR
Tension Splices..............................4 AWG–556.5 kcmil
Two-Piece ACSR
Tension Splices..............................2 AWG–556.5 kcmil
Cutting Capacities
Copper and Aluminum Cable............... 40 mm (1-1/2")
ACSR .............................................954 kcmil (Cardinal)
Standard Guy Strand..............................................5/8"
EHS Guy Strand .....................................................1/2"
Ground Rod..............................................13 mm (1/2")
Rebar (schedule 60)..................................13 mm (1/2")
Threaded Rod...................................... 1/4", 3/8", 1/2",
4 mm, 5 mm, 6 mm, 8 mm, 10 mm
DIN Rail...........................35 x 7.5, 32 x 15 x 9, 35 x 15
Punching Capacities
Round ...............144.1 mm (5-5/8") in 10 ga. mild steel
Rectangular ....68.0 mm x 138.0 mm (2.677" x 5.433")
Square ..........138.0 mm x 138.0 mm (5.433" x 5.433")
Accessories required to punch 4-1/2" through 5-5/8":
12185 spacer, 04686 bushing, and 03170 sleeve
4
5
6
7
8
1
2
3

E12CCX 12-ton Battery-powered, High-speed 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 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:
• Remove battery before changing
dies, adapters, or jaws.
• Keep hands away from the crimp-
ing tool head when crimping.
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, 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.
Crimping
Setup
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Select the appropriate set of die adapters and dies.
4. Install the adapters and dies—one set in each
groove. Lock the die adapters in place with the
detents.
Important: Die adapters must be locked into place
or the die detents will be damaged.
5. Visually check the dies to ensure that they are
aligned correctly so that they will complete the
crimping operation.
6. Close the tool head.
Die Adapter Detents:
Press and slide the adapter
into place. Release to lock.

E12CCX 12-ton Battery-powered, High-speed Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Operation (cont’d)
Crimping (cont’d)
Preparing the Cable
Follow the lug manufacturer’s instructions for appropri-
ate cable strip length.
CRIMPING DIRECTION
1ST COMPRESSION
CRIMPING DIRECTION
SIDE A
CRIMPING DIRECTION
SIDE B
1ST COMPRESSION
SIDE A
1ST COMPRESSION
SIDE B
Battery Condition
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.
Crimping Procedure
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.
An incomplete crimp can cause a re.
• Use proper die, connector, and cable combinations.
Mismatched combinations can result in an incom-
plete crimp.
• The crimping tool automatically retracts when a
complete crimp has been achieved. If you do not
hear a “pop,” the crimp is incomplete.
Failure to observe this warning could result in severe
injury or death.
1. Press the latch and open the tool head.
2. Insert the properly assembled connector into the
tool head.
3. Close the tool head.
4. Pull the trigger to make the crimp.
5. Hold the trigger down until the crimper achieves
pressure relief.
Notes: Pressure relief occurs at approximately
106 kN bar (12 tons). If you do not hear a “pop,”
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.
6. The ram returns automatically.
7. 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.
8. Position the crimper for the next crimp. Repeat
Steps 4 through 6 for the number of crimps as
described in this manual.
9. Open the crimping head and remove the connector.
Notes: If it is necessary to retract the ram before a
crimp cycle is completed, push the retract button.
Pushing the retract button will result in complete retrac-
tion of the ram.
After completing the last crimp on an aluminum
connector, wipe off the excess oxide inhibitor.

E12CCX 12-ton Battery-powered, High-speed Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Operation (cont’d)
Cutting
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.
Setup
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Select the appropriate set of blades, using the
table provided on this page.
4. Install one blade in each groove. Slide the tab into
the slots in the ram and head. Lock them in place
with the W-type detents.
5. Visually check the blades to ensure that they are
aligned correctly so that they will complete the
butting operation.
6. Close the tool head.
Setup for Din Rail Cutters
1. Install both blades in the movable head.
2. Close the head.
3. Slide one blade over until it engages in the W-type
detent in the ram slot. Slide the other blade over
until it engages in the W-type detent in the head slot.
Accessory Table
Task Blade
Copper and aluminum
26 mm (1.00") max. UC26
Copper and aluminum
40 mm (1.56") max. UC40
ACSR
Copperweld
ACAR
Guy strand
EHS guy strand
Ground rod
Anchor rod
Soft bolts
Rebar
UCACSR
Threaded rod Threaded rod
DIN rail DIN rail
Detents:
Press and slide the
adapter and/or die
into place.
Release to lock.
Cutting Procedure
1. Press the latch and open the tool head.
2. Position the item to be cut in the tool head.
3. Close the tool head.
4. Pull the trigger to cut the item.
5. Release the trigger when the cut is complete.
6. The ram returns automatically.

E12CCX 12-ton Battery-powered, High-speed Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Operation (cont’d)
Punching
Electric shock hazard:
Do not use this tool as a punch driver
on or near live circuits. This includes,
but is not limited to, the following
circumstances:
• Energized electrical lines
• Energized circuit breaker panels
and fuse boxes
• Junction boxes with energized
circuits
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.
Do not attempt to punch a hole
through two or more thicknesses of
material. This will bend or break the
draw stud, and could throw parts with
great force.
Failure to observe this warning could
result in severe injury or death.
A component failure could throw
broken parts.
• Do not allow anyone to stand in
front of the punch.
• Close access doors or covers on
any equipment that is in line with
the punch.
Failure to observe this warning could
result in severe injury or death.
Set up the tool properly. An improper setup could
cause a component to fail and strike nearby
personnel with great force.
• Thread the punch completely onto the draw stud.
All of the punch threads must be engaged by the
draw stud threads. Incomplete assembly could
cause a component failure.
• Use only Greenlee punches, dies, and draw studs.
Other manufacturers’ components might not with-
stand the forces generated by this punch driver.
Failure to observe these warnings could result in
severe injury or death.

E12CCX 12-ton Battery-powered, High-speed Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Operation (cont’d)
Punching (cont’d)
Setup and Punching Procedure
1. Open the tool head.
2. Remove any accessories from the tool head.
3. Install the punch driver so that the drive piston is
toward the yoke, as shown.
4. Close the tool head.
5. Select the punch, die, and draw stud to make the
appropriate size hole. Refer to the illustrations on
the following pages.
6. Determine and mark the exact location for the hole.
Use a Greenlee Kwik Stepper®drill bit to drill a hole
that is slightly larger than the draw stud. This is the
pilot hole.
7. Push the retract button and hold the button until the
ram is completely retracted.
8. Thread the 3/4" draw stud or 3/4" adapter com-
pletely into the punch driver. Refer to the illustra-
tions on the following pages.
Notes: For a punch and die with a 3/8" center hole,
thread the 3/8" draw stud into the end of the 3/4"
adapter.
For 4" and larger punch and die, add the bushing
to the die, slide the spacer over the 3/4" draw stud,
and install the 1-1/8" sleeve.
9. Install a spacer, if necessary. Refer to the illustra-
tions on the following pages.
10. Slide the die over the draw stud with the open end
of the die facing away from the punch driver.
11. Insert the draw stud through the pilot hole.
12. Thread the punch onto the draw stud with the
cutting surfaces of the punch facing the material.
Tighten the punch by hand until the spacer, die,
material, and punch contact each other.
Note: All of the punch threads must be engaged by
the draw stud threads. If any of the punch threads
are not engaged, disassemble the setup, remove the
spacer, and reassemble the setup.
Note: A “popping” sound indicates that the tool
has reached relief pressure. This may indicate that
the attempted operation is beyond the capacity of
the tool.
13. Pull the trigger.
14. Release the trigger when the punch completes the
hole. The ram returns automatically.
15. Unscrew the punch. Remove slugs from the die.
Remove the spacer and unscrew the draw stud.