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Greenlee GATOR EK425L User Manual

Greenlee GATOR EK425L
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INSTRUCTION MANUAL
GATOR
®
EK425L
Battery-powered
Crimping Tool
52047089 REV 5 © 2013 Greenlee Textron Inc. 9/13
Serial Number
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
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Greenlee GATOR EK425L Specifications

General IconGeneral
BrandGreenlee
ModelGATOR EK425L
CategoryPower Tool
LanguageEnglish

Summary

Description

Safety

Purpose of this Manual

Manual's intent to familiarize personnel with safe operation and maintenance.

Important Safety Information

Safety Alert Symbol and Signal Words

Defines the safety alert symbol and signal words (Danger, Warning, Caution) for hazard severity.

Eye Protection Warning

Warns about the need for eye protection to prevent serious injury from flying debris or oil.

Skin Injection Hazard Warning

Warns against checking leaks with hands due to high-pressure oil puncturing skin.

Flammable Liquids Warning

Warns against using solvents or flammable liquids for cleaning the tool body.

General Operating Safety Warning

Emphasizes understanding all instructions and safety information before operating or servicing.

Electric Shock Hazard Warning

Warns that the tool is not insulated and requires PPE when near energized lines.

Incomplete Crimp Hazard

Warns that an incomplete crimp can cause fire; describes indicators of a complete crimp.

Important Safety Information

Pinch Points Warning

Warns about pinch points when changing dies or operating the tool, advising battery removal.

Battery Disposal Warning

Warns against disposing of batteries in fire due to explosion and fume hazards.

Battery Handling Precautions

Details precautions for battery terminals, immersion, conductive objects, and moisture.

Tool Damage Warning

Warns to inspect tool and dies for damage and replace worn parts to prevent breakage.

Battery Storage and Charging Precautions

Advises on battery storage temperatures, charger compatibility, and not opening the battery.

Usage Limitations and Precautions

Advises on tool usage limits, cooling, avoiding vises, handling in wet environments, and intended purpose.

Maintenance Precautions

States that only maintenance described in the manual should be performed.

Identification

Tool Components Identification

Lists and illustrates numbered components of the crimping tool for identification.

Specifications

Tool and Charger Specifications

Provides dimensional, weight, force, oil type, temperature range, and charger details.

Operation

Pre-Operation Warnings

Reiterates warnings about tool inspection, electric shock, eye protection, and pinch points.

Usage Limitations

Details tool usage limits, cooling, avoiding vises, and handling in wet environments.

Battery Charging

Instructs to read the battery charger manual for charging instructions.

LED Indicators

Explains the function of the white LED work light and the red LED indicator signals.

Pressure Sensor Function

Describes how the pressure sensor alerts the user of incomplete crimps via LED and audible signals.

Die and Connector Selection

Die Selection Guide

Lists compatible die series for the standard die opening and installation guidance.

Preparing Cable for Crimping

Instructs to follow lug manufacturer's guidelines for appropriate cable strip length.

Crimping Procedure

Step-by-step guide on inserting conductor, activating tool, and completing crimps.

Incomplete Crimp Hazard Warning

Reiterates the fire hazard of incomplete crimps and indicators of completion.

CJ22 Jaw and KA22/KC22-type Die Selection

Die Compatibility Notes

Specifies tool classification with CJ22 jaws and KA22/KC22 dies, and crimping force.

Dies for Copper Connectors

Lists catalog numbers, UPCs, cable sizes, and color codes for copper dies.

Dies for Dual-rated Aluminum Connectors

Lists catalog numbers, UPCs, cable sizes, and color codes for aluminum dies.

Connector Selection Guide

Lists compatible connector brands for CJ22 jaws with KC22 and KA22 dies.

Maintenance

Daily Maintenance Checks

Daily pre-use inspections for wear, damage, leaks, and head assembly rotation.

Post-Use Cleaning and Storage

Instructions for cleaning housing, retracting ram, and storing the tool after use.

Monthly Maintenance

Monthly tasks include thorough cleaning and checking the oil level.

Annual or 10,000 Crimps Maintenance

Annual tasks include replacing hydraulic oil and tool inspection by authorized service.

Checking the Oil Level

Procedure for checking and refilling the hydraulic oil reservoir.

Service Center Note

Important note that relief valve adjustments must be performed by an authorized service center.

Troubleshooting

Before You Begin Troubleshooting

Initial steps include checking battery charge and cleaning contacts.

Troubleshooting Table

Lists common problems, possible causes, and probable remedies for tool operation issues.

Illustrations

Main Assembly Diagram

Exploded view diagram of the main components of the crimping tool.

Illustrations

Pump Housing, Relief Valve, and Piston Pump Assemblies

Exploded view diagrams of the pump housing, relief valve, and piston pump units.

Motor Assembly Diagram

Exploded view diagram of the tool's motor assembly components.

Illustrations

Ram Unit Diagram

Exploded view diagram of the ram unit components.

Illustrations

Crimping Jaw Units Diagrams

Exploded view diagrams of different crimping jaw units (CJD3BG, CJD3O, CJD3, CJK Kearney).

Parts List

Main Parts List

Detailed list of parts for the tool's main assemblies with part numbers and quantities.

Optional Accessories Parts List

Lists parts for crimping jaw units and related kits.

Optional Accessories Illustrations and Parts

CJ22 Jaw Unit Illustration and Parts

Exploded view and parts list for the CJ22 crimping jaw unit.

CJXPJ Jaw Unit Illustration and Parts

Exploded view and parts list for the CJXPJ crimping jaw unit.

CJB Single-use Lock Cutter Illustration and Parts

Exploded view and parts list for the CJB single-use lock cutter.

Jaw Pivot and Die Retaining Pin Kits

Illustrations and parts for jaw pivot kits and die retaining pin kits.

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