Textron Greenlee EK50ML User manual

INSTRUCTION MANUAL
EK50ML
Battery-powered
Crimping Tool
52068455 REV 2 © 2015 Greenlee Textron Inc. 3/15
Serial Number
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
2
Description
The EK50ML Battery-powered Crimping Tool is a
hand-held, self-contained crimping tool intended to
crimp cable using Greenlee’s Kwik Cycle®9 and
CrimpALL®die sets as well as some competitors’
diesets.
U.S. patent pending.
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:
EK50ML Battery-powered Crimping Tool
Keep this manual available to all personnel.
Do not discard this product or throw away!
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
Battery Charger .............................................................. 6
Operation.................................................................... 7–8
Maintenance................................................................... 9
Troubleshooting............................................................ 10
Die Holders................................................................... 11
CrimpALL®Interchangeable Die Sets.....................11-13
Illustration..................................................................... 14
Parts List .................................................................15-16
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.
CrimpALL and Kwik Cycle are registered trademarks of
TextronInnovations Inc.
Teon is a registered trademark of Dupont.
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
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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
electrical lines, use proper personal
protective 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.
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.
Improper combinations can result in an incomplete
crimp.
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.
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.
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
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IMPORTANT SAFETY INFORMATION
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.
• Allow approximately 3 to 5 minutes of time to cool
down as tool automatically switches off when it
gets too hot.
• 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 122 °F
(50°C) or less than –4 °F (–20 °C). 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.
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
5
Identification
1. Crimping Dies
2. LED Work Light (white)
3. Crimping Head
4. LED Indicator (red)
5. Battery Cartridge
6. Battery Lock
7. Trigger
Specifications
Crimping Tool
Length (with battery)............................................................................... 9.93" (252.22 mm)
Width ............................................................................................................ 2.5" (63.5 mm)
Depth.......................................................................................................... 3.6" (91.44 mm)
Weight......................................................................................................... 2.18 lb (0.98 kg)
Crimping Force..........................................................................................1.53 tons (15 kN)
Recommended Operating Temperature Range................14 °F to 104 °F (–10 °C to 40 °C)
Battery
Charging Time ........................................................................................................... 40 min
52068605 Battery, 10.8V 1.5 Ah li-ion (16.2 Wh)
52068603 Charger, 10.8V li-ion batteries, 110V
52068604 Charger, 10.8V li-ion batteries, 230V
4
5
7
6
1
3
2
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
6
Battery and Charger
i
i
i
i
i
100%
75%
50%
25%
0%
% Charge Remaining
1. Charger is plugged into socket.
2. Battery is charging.
3. Battery is fully charged.
4. Battery is defective.
5. Battery is too hot or too cold.
6. Charger is defective.
2
3
4
5
1
6
Remove battery only after unplugging charger from
socket.
Failure to observe this precaution may result in injury
and property damage.
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
7
Operation
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.
Electric shock hazard:
This tool is not insulated. When
using this unit on or near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning
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.
• Allow approximately 3 to 5 minutes of time to cool
down as tool automatically switches off when it
gets too hot.
• Do not secure this tool in a vise. This tool is
designed for hand-held operation.
• 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 Work Light (white)
This LED automatically turns on when the trigger is
pulled. It remains on for 10 seconds after the trigger is
released.
LED Indicator (red)
This tool is equipped with a special circuit board incor-
porating several important features to inform the user
about the current status of the unit. The LED signals in
the following cases:
When What it means
2 x
After
inserting
the battery
Battery is
inserted in tool
20 sec
After
working
cycle
Low battery
20 sec/2 Hz
Contact Greenlee
service
20 sec/5 Hz 20 sec/5 Hz
Tool has become
too hot
1 x 1 x
After
interruption
Error – manual
interruption of
crimp cycle prior
to completion
3 x 3 x
After
working
cycle
Error – automatic
opening of tool
due to exceeding
crimp force
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
8
Operation (cont’d)
Installing Dies
1. Select the proper dies for the intended crimp.
2. Slide the die into the crimping head and secure with
screw.
3. Properly position the second die. Repeat Step 2.
Preparing Cable
Follow the lug manufacturer’s instructions for appropri-
ate cable strip length.
Crimping Direction
First Compression
Crimping Direction
SIDE A
Crimping Direction
SIDE B
First Compression
SIDE A
First Compression
SIDE B
Crimping Cable
1. Insert the properly assembled connector into the
crimping head.
2. Pull the trigger to make the crimp.
3. Hold the trigger down until the crimping tool auto-
matically completes the cycle.
4. The crimp cycle automatically stops when com-
plete, and the jaws automatically retract when the
trigger is released.
5. Position the crimping tool for next crimp. Repeat
Steps 2 and 3 for the number of crimps as
described in this manual.
An incomplete crimp can cause a re.
Use proper die, connector, and cable combinations.
Improper combinations can result in an incomplete
crimp.
Failure to observe these warnings could result in
severe injury or death.
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
9
Daily
Before use:
1. Inspect the tool for wear or damage, such as cracks,
gouges, or chips.
2. Inspect the tool for damage.
After use:
1. Use a damp cloth and mild detergent to clean the
housing. Allow the housing to dry.
2. Place the tool in the carrying case and store in a
cool, dry place.
3. If necessary, recharge the batteries. Refer to the
instructions supplied with the battery charger.
Monthly
Thoroughly clean all surfaces.
Annually or After 35,000 Crimps
Send the tool to a Greenlee Authorized Service Center
for inspection.
Note: For Warranty Service or Repair, contact Greenlee
customer service at 800-435-0786.
Maintenance
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 use solvents or ammable
liquids to clean the tool body.
Solvents or ammable liquids could
ignite and cause serious injury or
property damage.
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.
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EK50ML Battery-powered Crimping Tool
Greenlee / A Textron Company
10
Problem Possible Cause Probable Remedy
Tool is inoperative. Continuous use causes tool to become
too hot and automatically switch off.
Allow approximately 3 to 5 minutes of
time to cool down.
Dirt, contaminants, etc., in jaw area
oftool.
Clean tool.
Tool components worn or damaged. Return tool to a Greenlee Authorized
Service Center.
Motor is inoperative. Low or uncharged battery. Try known charged battery. Inoperative
battery may be discharged or may have
reached life expectancy.
Broken switch components. Return tool to a Greenlee Authorized
Service Center.
LED glows for 20 seconds. Battery charge low. Charge or replace battery.
Note: For Warranty Service or Repair, contact Greenlee customer service at 800-435-0786.
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.
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