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INSTRUCTION MANUAL
®
GATOR EK22GL
Battery-powered,
High-speed Crimping Tool
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 4521.5 © 2001 Greenlee Textron IM 1552 10/01
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EK22GL Battery-powered, High-speed Crimping Tool Table of Contents Description Description ..................................................................... 2 The EK22GL Battery-powered, High-speed Crimping Tool is a hand-held, self-contained crimping tool Safety ............................................................................. 2 intended to crimp copper cable with K22-type and Purpose of this Manual .................................................. 2 W-type dies. Important Safe
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EK22GL Battery-powered, High-speed Crimping Tool IMPORTANT SAFETY INFORMATION SAFETY Wear eye protection when operating ALERT or servicing this tool. SYMBOL Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil. 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 inf
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EK22GL Battery-powered, High-speed Crimping Tool Operation Charging the Battery Read the instructions supplied with the battery charger. Electric shock hazard: This tool is not insulated. When Battery Condition using this unit near energized Battery Load Display Battery Condition electrical lines, use proper personal Momentary illumination at Normal or operating protective equipment. beginning of crimp charge level Failure to observe this warning can Flickering at point of Normal or operating re
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EK22GL Battery-powered, High-speed Crimping Tool Dies and Connectors Die Selection Crimps made on copper cable with Greenlee K22-type dies and the connectors listed here are UL classified and CSA certified. Refer to “Connector Selection” for brand names and model numbers of appropriate lugs as well as crimping instructions. W-type dies can be used to crimp #6 AWG to 4/0 AWG alumi- num or copper cable. Part UPC Cable Color Number Number Size Code K22-0 03079 #8 AWG Red K22-1 03080 #6 AWG Blue K22
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EK22GL Battery-powered, High-speed Crimping Tool Maintenance Monthly Each Operating Day 1. Thoroughly clean all surfaces. Before use: 2. Check the oil level. 1. Inspect dies for wear or damage such as cracks, gouges, or chips. 3. Oil the bolt joints. 2. Inspect the tool for damage or leaks. If damage is Annually or After 10,000 Crimps detected, return the tool to an authorized Greenlee service center for inspection. 1. Change the hydraulic oil. 2. Return the tool to an authorized Greenlee servic
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EK22GL Battery-powered, High-speed Crimping Tool Troubleshooting Before You Begin 2. Use a nonflammable contact cleaner or pencil eraser to clean the electrical contacts on the battery 1. Make sure that the battery is charged. Recheck the and crimping tool. battery after several minutes to make sure the battery is holding its charge. 3. Reinstall the battery and check the tool again. Problem Probable Cause Probable Remedy Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool. of
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EK22GL Battery-powered, High-speed Crimping Tool Disassembly Main Components Pump 1. Remove the battery. 1. Use a hooked tool to remove the reservoir O-ring (80). Gently tug it over the reservoir. 2. Drive out the pin (37). Remove the die holder assembly (28). 2. Remove the reservoir (74). 3. Loosen two screws (24). 3. Remove the pump piston (152). 4. Unscrew and remove crimping head assembly. 4. Remove the screw plug (151), washer (153), pump piston (150), valve stem (156), and spring (155). 5.
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EK22GL Battery-powered, High-speed Crimping Tool Assembly Motor, Gearbox, and Bearing Main Components 1. Install two fillister head screws (112) into the spacer 1. Remove the protective plastic bag from the (not numbered) and motor (90). Tighten the screws. electronics subassembly. Insert the LED into the LED bushing (59). 2. Install four screws (not numbered) into the gear housing (94). Tighten the screws. 2. Lay the gear housing/motor subassembly into the right half of the housing. Insert the
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EK22GL Battery-powered, High-speed Crimping Tool Illustration Greenlee Textron / Subsidiary of Textron Inc. 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070 12 13 15 29 21 18 26 14 19 16 27 31 17 24 29 23 20 19 33 25 34 36 34 33 30 29 34 24 28 35 33 37 31 29 23 36 34 23 33 22 32 30
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EK22GL Battery-powered, High-speed Crimping Tool Illustration Greenlee Textron / Subsidiary of Textron Inc. 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070 74 76 82 75 77 78 79 95 83 80 98 97 122 81 123 129 121 124 111 120 155 130 125 156 112 126 73 127 72 90 150 128 154 153 110 99 140 105 151 106 94 152 109 141 93 54 104 101 61 107 91 92 108 96 100 103 102
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EK22GL Battery-powered, High-speed Crimping Tool Parts List Key Part No. Description Qty 7 500 7151.3 Circuit board, programmed................................................................ 1 9 500 2948.7 Decal, identification ........................................................................... 1 10 500 2950.9 Decal, warning................................................................................... 1 11 500 6214.0 Decal, pinch hazard..............................................
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EK22GL Battery-powered, High-speed Crimping Tool Parts List (cont’d) Key Part No. Description Qty 500 1354.8 Pump housing, reservoir assembly (includes items 72–83) 72 500 4144.4 Threaded bushing ............................................................................. 1 73* 500 4143.6 O-ring ................................................................................................ 1 74 500 5861.4 Hydraulic reservoir .....................................................................
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EK22GL Battery-powered, High-speed Crimping Tool Parts List (cont’d) Key Part No. Description Qty 500 1593.1 Relief valve assembly (includes items 120–130) 120 500 5860.6 Washer .............................................................................................. 1 121* 500 4134.7 O-ring ................................................................................................ 1 122* 500 5862.2 Seal ..................................................................................
