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.
EK22GL Battery-powered, High-speed Crimping Tool Table of Contents Description Description ..................................................................... 2 Safety ............................................................................. 2 Purpose of this Manual .................................................. 2 Important Safety Information ...................................... 3–4 Identification ................................................................... 5 Specifications ............
EK22GL Battery-powered, High-speed Crimping Tool IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL Wear eye protection when operating or servicing this tool. 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.
EK22GL Battery-powered, High-speed Crimping Tool Greenlee Textron / Subsidiary of Textron Inc. 4 4455 Boeing Dr.
EK22GL Battery-powered, High-speed Crimping Tool Identification 10 11 7 1 6 5 EK22GL 1. Housing 2. Retract Button 3. Battery Cartridge 4. 5. 6. 7. 8. 9. 10. 11. 12. 2 4 Trigger Battery Load Display Locking Flange Die Release Buttons W-type Die Detents Crimping Dies Crimping Head Oil Reservoir Oil Plug 3 Specifications Crimping Tool Length ........................................................................................... 314 mm (12-3/8") Width .................................................
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 using this unit near energized electrical lines, use proper personal protective equipment. Failure to observe this warning can result in severe injury or death.
EK22GL Battery-powered, High-speed Crimping Tool Operation (cont’d) Preparing Cable 6. The crimping tool returns automatically. 7. Position the crimping tool for next crimp. Repeat Steps 4 through 6 for the number of crimps as described in this manual. 8. Open the crimping head and remove the connector. Notes: If it is necessary to retract the ram before a crimping cycle is completed, push the retract button. Pushing the retract button will result in the complete retraction of the ram.
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 aluminum or copper cable.
EK22GL Battery-powered, High-speed Crimping Tool Maintenance Each Operating Day Monthly 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. 1. Thoroughly clean all surfaces. 2. Check the oil level. 3. Oil the bolt joints. Annually or After 10,000 Crimps 1. Change the hydraulic oil. 2.
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 and crimping tool. 3. Reinstall the battery and check the tool again. 1. Make sure that the battery is charged. Recheck the battery after several minutes to make sure the battery is holding its charge. Problem Tool is inoperative. Probable Cause Probable Remedy Dirt, contaminants, etc., in ram area of tool. Clean tool.
EK22GL Battery-powered, High-speed Crimping Tool Disassembly Main Components Pump 1. Remove the battery. 2. Drive out the pin (37). Remove the die holder assembly (28). 3. Loosen two screws (24). 4. Unscrew and remove crimping head assembly. 5. Remove the spring (18) and piston (15). Replace the piston O-ring (12) and piston backup ring (13). 6. Unscrew two tank cover screws (55) and remove the tank cover. 7. Remove the hydraulic reservoir plug (76) and drain the hydraulic fluid. 8. Reinstall the plug. 9.
EK22GL Battery-powered, High-speed Crimping Tool Assembly Main Components Motor, Gearbox, and Bearing 1. Remove the protective plastic bag from the electronics subassembly. Insert the LED into the LED bushing (59). 2. Lay the gear housing/motor subassembly into the right half of the housing. Insert the circuit board into the circuit board slot so that the wires and chip face in the direction of the trigger. 3. Lay the wires into the case. Be sure that the wires will not be pinched. 4.
EK22GL Battery-powered, High-speed Crimping Tool Greenlee Textron / Subsidiary of Textron Inc. 13 4455 Boeing Dr.
EK22GL Battery-powered, High-speed Crimping Tool 23 37 28 30 22 23 31 33 29 20 19 34 27 32 33 29 34 21 30 35 36 33 34 31 23 26 36 34 33 19 24 29 17 24 16 25 29 14 18 15 13 12 Illustration Greenlee Textron / Subsidiary of Textron Inc. 14 4455 Boeing Dr.
EK22GL Battery-powered, High-speed Crimping Tool 108 106 130 103 102 101 92 96 151 54 140 141 72 61 73 154 83 79 91 152 153 150 156 78 155 77 122 75 82 123 93 129 81 121 109 124 100 120 80 74 105 125 126 99 127 128 107 104 76 112 94 111 110 97 98 90 95 Illustration Greenlee Textron / Subsidiary of Textron Inc. 15 4455 Boeing Dr.
EK22GL Battery-powered, High-speed Crimping Tool Parts List Key 7 Part No. 500 7151.3 Description Qty 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 ............................................
EK22GL Battery-powered, High-speed Crimping Tool Parts List (cont’d) Key Part No. 500 1354.8 Description Pump housing, reservoir assembly (includes items 72–83) Qty 72 500 4144.4 Threaded bushing ............................................................................. 1 73* 500 4143.6 O-ring ................................................................................................ 1 74 500 5861.4 Hydraulic reservoir .....................................................................
EK22GL Battery-powered, High-speed Crimping Tool Parts List (cont’d) Key Part No. 500 1593.1 Description Relief valve assembly (includes items 120–130) Qty 120 500 5860.6 Washer .............................................................................................. 1 121* 500 4134.7 O-ring ................................................................................................ 1 122* 500 5862.2 Seal ..................................................................................
