GATOR Battery-powered In-line X Tools

Transcription

1 SERVICE MANUAL (EKLX shown) GATOR Battery-powered In-line X Tools Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Register this product at REV 0 Greenlee Tools, Inc. /

2 Table of Contents Safety... Purpose of this Manual... Other Publications... Important Safety Information... Main Illustrations All Tools... Main Parts List All Tools... Head and Ram Illustrations and Parts Lists EKATILX... EKATILX... 0 EKIDLX, EKIDCLX... EK0LX... EKLX, EKLX... EKLX... ES0LX, ESLX, ESFLX... ESCLX... ESCLX... 0 ESCHLX... ESC0LX... ESGLX... ESGLX... ETSLX... ETSLX... LS00X... 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 authorized Greenlee service personnel with the service parts for the Greenlee listed on this page. Keep this manual available to all personnel. Replacement manuals are available upon request at no charge at Other Publications Operation Manuals EKATILX EKFTILX EKIDCLX EKIDLX EK0LX 000 EKLX 0000 EKLX 000 EKLX 000 ES0LX 000 ESLX 000 ESFLX ESCLX ESCHLX ESCLX ESC0LX ESGLX 000 ESGLX 000 ETSLX 000 ETSLX 000 LS00X 0 Do not discard this product or throw away! For recycling information, go to All specifications are nominal and may change as design improvements occur. Greenlee Tools, Inc. shall not be liable for damages resulting from misapplication or misuse of its products. GATOR is a registered trademark of Greenlee Tools, Inc. KEEP THIS MANUAL Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

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, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. Skin injection hazard: Do not use hands to check for oil leaks. Oil under pressure easily punctures skin. If injured, seek medical attention immediately to remove oil. Failure to observe this warning could result in serious injury, gangrene, or death. 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. Do not use solvents or flammable liquids to clean the tool body. Solvents or flammable liquids could ignite and cause serious injury or property damage. Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage. Do not dispose of batteries in a fire. They will vent fumes and may explode. Failure to observe this warning could result in severe injury from harmful fumes or burns from flying debris. Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Refer also to the Operation Manual, which is listed under Other Publications. Failure to observe this warning could result in severe injury or death. 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. Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil. Note: Keep all decals clean and legible, and replace when necessary. Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

4 Main Illustrations All Tools 0 All housing screws screwed in completely. T=. Nm max Screw on hand-tight. Then turn out until the radial hole is free to screw in the anti-twist screw. T= Nm T=0 Nm 0 T= Nm max. 0 max. T= Nm T=. Nm 00 Motor Assembly 0 Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

5 Main Illustrations All Tools (cont d) Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly All tools except EKATILX, EKFTILX, EKIDLX, EKIDCLX, ESCLX, ESCLX, ESC0LX, ESCHLX, ESGLX, ESGLX, and LS00X 0 T= Nm 0 T= Nm T= Nm T=. Nm 0 0 EKATILX and EKFTILX T= Nm 0 Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

6 Main Illustrations All Tools (cont d) Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly EKIDLX, EKIDCLX, ESCLX, ESCLX, ESCHLX, ESC0LX, and ESGLX T= Nm 0 T= Nm T= Nm 0 T= Nm 0 T=0. Nm T=. Nm T=0. Nm 0 T= Nm 0 ESGLX and LS00X T= Nm T=. Nm 0 Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

7 Main Parts List All Tools 00 Relief lever kit (includes, ) Screw... Relief valve lever... 0 Control Board (EKLX, EKLX)... 0 Control Board (EK0LX)... 0 Control Board (EKLX) Control Board (EKIDLX, EKIDCLX)... 0 Control Board (ETSLX, ETSLX)... 0 Control Board (ESLX, ESFLX,... ES0LX, ESGLX) 0 Control Board (ESGLX)... 0 Control Board (ESCLX, ESC0LX,... ESCLX, ESCHLX) 00 Control board (EKATILX, EKFTILX) Control board (LS00X)... 0 Display Screen (LS00X)... * Seal Sensor (crimpers, LS00X)... 0 Screw (cutters) Ring (EKIDLX, EK0LX, EKIDCLX,... EKLX,ESCLX, ESCLX, ESGLX,. ESGLX, ETSLX, ESCHLX, ESC0LX) 00 Ring (EKLX, EKLX, ETSLX) Ring (ES0LX, ESLX, ESFLX,... LS00X) 00 Ring (EKATILX, EKFTILX)... * Felt seal... 0 Piston Pump Assembly ø.mm... (EKLX) (Includes 0 ) 000 Piston pump assembly ø.mm... (all others) (includes 0 ) 0 Piston pump... Spring... Piston pump housing... * Piston seal... Screw... Spring Relief valve unit (includes ) (all except EKIDLX, EKLX, EKIDCLX,. EKATILX, EKFTILX, ESCLX, ESCLX, ESCHLX, ESC0LX, ESGLX,. ESGLX, ETSLX, LS00X)... 0 Relief valve unit (includes ) (EKATILX, EKFTILX, EKIDCLX, ESC0LX, EKIDLX, EKLX, ETSLX, ESCLX) Relief valve unit (includes ) (ESCLX, ESGLX, ESCHLX) Relief valve unit (includes ) (ESGLX, LS00X) Valve seat... Needle valve... Plunger... Spring... Washer... * O-ring... * O-ring... Pressure relief... Screw Pump housing unit (includes, 0 )... (EKIDLX, ESCLX, ESGLX, ESC0LX,. ESCLX, EKIDCLX) 0 Pump housing unit (includes, 0 )... (EK0LX, ETSLX) 00 Pump housing unit (includes, 0 )... (EKLX, EKLX, ETSLX) 0 Pump housing unit (includes, 0 )... (EKLX) 00 Pump housing unit (includes, 0 )... (ES0LX, ESLX, ESFLX) 00 Pump housing unit... (includes,, ) (ESGLX) 00 Pump housing unit... (includes,, ) (LS00X) 00 Pump Housing Unit (includes, 0 )... (EKATILX, EKFTILX)... Ball... Screw... Shaft... Bushing... Bearing... O-ring... Plate... Screw... Solenoid... 0 Clamp, nylon, 0 pack... 0 Clamp... Screw Threaded bushing... Pump block Threaded bushing Screen... 0 Reservoir (all others) Reservoir (ESGLX, LS00X,... EKATILX, EKFTILX) * O-ring... Washer... Threaded bushing... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

8 Main Parts List All Tools (cont d) 00 Valve kit (includes 0 ) 0 Valve seat... Spring... Washer... Needle valve... Spring... Washer... Screw... Top Housing unit (includes ) (all except LS00X)... 0 Housing unit (includes 0 ) (LS00X)... Ring... 0 Screw Screw... Compression spring, DA. x L.0... Trigger link... Housing half... Housing half... Relief valve button... Trigger cover... Stud Motor assembly (includes -) (ESCLX)... 0 Motor assembly (includes 0) (ALL OTHERS)... Retaining ring Pin... Motor cap... Disc housing... Disc... Screw... Gear lube,. g... Motor adapter... Electric motor... 0 Screw... O-ring... Plate In-line GATOR decal... 0 In-line Intelli-PUNCH decal (LS00) FCC X version decal Identification decal (EKIDCLX) Identification decal (EKATILX)... 0 Identification decal (EKFTILX)... 0 Identification decal (EKIDLX)... 0 Identification decal (EK0LX)... 0 Identification decal (EKLX)... 0 Identification decal (EKLX)... 0 Identification decal (EKLX)... 0 Identification decal (ES0LX)... 0 Identification decal (ESLX)... 0 Identification decal (ESFLX) Identification decal (ESCLX)... 0 Identification decal (ESCHLX)... 0 Identification decal (ESCLX)... 0 Identification decal (ESC0LX)... 0 Identification decal (ESGLX) Identification decal (ESGLX)... 0 Identification decal (ETSLX)... 0 Identification decal (ETSLX) Identification decal (LS00X) Warning decal, crimping tool... 0 Warning decal, cutter... 0 Carrying strap 000 Carrying case (All others) 0 Carrying case (EKATILX, EKFTILX) 0 Carrying case (ESGLX) 00 Carrying case (LS00X) 00 Carrying pouch(eklx) 0 Connector compatibility decal (EKATILX) 0 Connector compatibility decal (EKFTILX) 00 Connector compatibility decal (EKIDLX,... EKIDCLX) 0 Connector compatibility decal (EK0L) 00 Connector compatibility tag (EKL) 00 Connector compatibility decal (EKL, EKL) * 00 Seal kit (includes items marked with an asterisk, bushings not included) 00 V battery.0 Ah 000 V battery.0 Ah 00 V charger 0 VAC 00 V charger 0 VAC 00 V charger VDC 00 V corded adapter 0 VAC 00 V corded adapter 0 VAC 0 Biodegradable hydraulic fluid Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

9 Head and Ram Illustration and Parts List EKATILX Quad point head assembly (includes ) 00 Cam yoke assembly... Roller bearings... Bearing retainers Compression spring Screw Fixed jaw Moving jaw Pivot roller Pivot pin Screw Head kit (includes, ) Head cover (LH)... Head cover (RH) Spring pin Spring pin... 0* O-ring (included in 00)... * Backup ring (included in 00) Piston Pin Compression spring Sleeve Bearing retainer kit (includes, ) Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

10 Head and Ram Illustration and Parts List EKFTILX Quad point flip-top head assembly (includes ) 00 Cam yoke assembly Latch (includes ) Moving jaw... Roller bearing... Bearing retainer Latch mounting pin... Latch nib (included in 00) Lock pin Side jaw roller Compression spring Ball screw Snap ring Screw Screw Set screw Spring pin... 0 Head cover... 0* O-ring (included in 00)... * Backup ring (included in 00) Piston Pin Compression spring Sleeve Bearing retainer kit (includes, ) Greenlee Tools, Inc. 0 Boeing Dr. Rockford, IL 0- USA --00

11 Head and Ram Illustration and Parts List EKIDLX, EKIDCLX Head and ram (includes -) 00 Head and ram, PVC coated (includes... ) 0 Fixed head 00 Fixed head, PVC coated... 0 Head and latch kit (includes, ) 000 Head and latch kit, PVC coated (includes, ) Fixed head... Latch head... 0 Fastener kit (includes -) 00 Fastener kit, PVC coated (includes ) Pin... Retaining ring... Spring... Screw... 0 Cone die... 0 Ram kit (includes ) Ram... 0 Sleeve Piston cup, small... Bushing... Adapter disk... 0 Spring kit (includes, ) Compression spring... Spring Hex screw, M x... * O-ring (included in 00)... * Piston backup ring (included in 00)... * O-ring,. x. N0 (included in 00)... 0* Backup ring (included in 00)... * O-ring (included in 00)... 0 Head kit, PVC coated Coated (includes -) Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

12 Head and Ram Illustration and Parts List EK0LX Head and ram (includes ) 0 Ram kit (includes,,, ) Shoulder bolt... Disc... Spring Fixed head... 0 Hardware kit (includes,, ) Screw... Retaining ring... 0 Pin... Spring Head and latch kit (includes, ) Movable head... Screw... Pin... Ram adapter... Latch head... Washer... * O-ring (included in 00)... 0* Piston backup ring (included in 00) Bushing... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

13 Ram Illustration and Parts List EKLX and EKLX Ram unit (includes ) Sheath... 0 Spring kit (includes ) Shoulder bolt... Disc... Compression spring... Washer... * O-ring (included in 00)... 0 Screw... Jaw holder Latch kit (includes ) Compression spring... 0 Locking pin... Compression spring... Pin Roller kit (includes, ) Roller... Ram Bushing with seal... * Seal bushing (included in 00)... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

14 Jaw Units Illustration and Parts List 0 CJ CJXPJ C B 0 CJB A 0 CJ crimping jaw unit for cul and UL classified crimps 0 CJXPJ crimping jaw unit (includes -) 0 CJB single-use lock cutter (includes -) 00 Jaw pivot kit (includes, ) Retaining ring... Pivot pin... A Jaw, sharp CJB... B Jaw, CJXPJ... C Jaw, CJ... 0 Extension spring... Jaw, flat CJB... 0 Die retaining pin kit (includes 0) Die retaining pin... Compression spring... Release button... 0 Retaining ring... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

15 Jaw Units Illustration and Parts List (cont'd) CJACSR 0 Jaw Assembly Cu/Al 0 Jaw Assembly ACSR Retaining ring... Pivot pin... Jaw... 0 Extension spring... Screw... Blade, ACSR... Blade, Guide... Screw... Blade Cu/Al... 0 Blade Kit, Cu/Al (includes, ) 0 Blade Kit, ACSR (includes ) CJCU Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

16 Jaw Units Illustration and Parts List (cont d) CJDBG CJDO CJD A A C 0A 0C 0D A A C 0 glued in with Loctite 0 (green) B 0 CJK Kearney 0B B 0 CJDBG crimping jaw unit (includes 0 ) 0 CJDO crimping jaw unit (includes 0 ) 00 CJD crimping jaw unit (includes 0 ) 00 CJK Kearney crimping jaw unit (includes 0, -) 0A Jaw, CJDBG... 0B Jaw, CJK... 0C Jaw, CJDO... 0D Jaw, CJD... 0 Extension spring Jaw pivot kit (includes, ) Retaining ring... Pin pivot... Bushing... Compression spring... Lock adapter... A 0 Jaw covers, CJDO/CJDBG (set of )... B 0 Jaw covers, CJK (set of )... C 00 Jaw covers, CJD (set of )... Bushing... 0 Ball, mm... Locking pin Die pin kit, W -style dies (includes ) 000 Die pin kit, Kearney-style dies (includes, ) Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

17 Head and Ram Illustration and Parts List EKLX Head and ram (includes ) 0 Ram Adapter disk... * O-ring (included in 00) Compression spring... 0 Pin kit (includes, ) Spring... Pin... Pin... 0 Die retainer kit (includes 0,, ) 0 Die retainer... Compression spring Screw Bottom crimp head... 0 Latch... 0 Top die holder... 0 Bottom die holder... Retaining ring... Die release button... Die retainer... 0 Roll Pin... Die release button... Locking pin... 0 Die holder kit (includes, ) Threaded stud... Pin Piston cup... * Backup ring (included in 00)... * O-ring (included in 00)... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

18 Head and Ram Illustration and Parts List ES0LX, ESLX, and ESFLX 0 ES0LX ESLX ESFLX NOTE: ESFLX blades have a dimple for identification 0 Head assembly, ES0LX (includes ) 0 Head assembly, ESLX (includes ) 0 Head assembly, ESFLX (includes ) 0 Ram kit (includes, ) Piston... Coil spring... Steel washer Hardware kit (includes,,, ) Retaining clip... Steel washer Screw Aluminum head... Screw... Pivot... 0 Retaining clip... Pivot... 0 Blade kit, ESLX (includes ) 0 Blade kit, ESFLX (includes ) 0 Blade kit, ES0LX (includes ) Fixed blade... Pivot bolt... Movable blade... Hex nut Bushing with seal... * Seal bushing (included in 00)... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

19 Head and Ram Illustration and Parts List ESCLX T=. Nm Head assembly (includes ) * Backup ring (included in 00)... * O-ring (included in 00) Piston cup... 0 Ram Kit (includes )... Screw... Piston rod... Spring... Shim... * O-ring (included in 00)... 0 Base Screw... 0 Block... 0 Link... 0 Hardware Kit (includes, )... Pin... Ring, retaining... 0 Blade holder... 0 Pivot pin Nut... 0 Blade Cover Kit (includes:,, 0)... Cover... Screw... 0 Screw... 0 Blade Kit (includes,, )... Screw... Blade... Guide... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

20 Head and Ram Illustration and Parts List ESCLX T=. Nm 0 T=. Nm 0 T=. Nm 0 Head assembly (includes 0) * Backup ring (included in 00)... * O-ring (included in 00) Piston cup... 0 Ram kit (includes )... Screw... Piston rod... Spring... Shim... * O-ring (included in 00)... 0 Base Screw... 0 Block... 0 Link... 0 Hardware kit (includes, )... Pin... Ring, retaining... 0 Blade holder... 0 Pivot pin Nut... 0 Blade Cover Kit (includes,, 0)... Cover... Screw... 0 Screw... Greenlee Tools, Inc. 0 Boeing Dr. Rockford, IL 0- USA --00

21 Head and Ram Illustration and Parts List ESCHLX T=. Nm 0 0 T=. Nm T=. Nm 00 Head assembly (includes 0) 0 Hood kit (includes 0) * Backup ring (included in 00)... * O-ring (included in 00) Piston cup... 0 Ram kit (includes )... Screw... Piston rod... Spring... Shim... * O-ring (included in 00)... 0 Base Screw... 0 Block... 0 Link... 0 Hardware kit (includes,)... Pin... Ring, retaining... 0 Blade... 0 Pivot pin Nut Cover... 0 Screw Screw... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

22 Head and Ram Illustration and Parts List ESC0LX 0 0 Head assembly (includes ) 0 Screw... 0 Piston rod Spring Shim... * O-ring (included in 00)... 0 Base Screw Block... 0 Link Pin Ring, retaining... 0 Blade... 0 Pivot pin Nut... 0 Cover... 0 Screw Screw... 0 Guide Screw Piston cup... * Bu ring (included in 00)... * O-ring (included in 00)... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

23 Head and Ram Illustration and Parts List ESGLX Head assembly (includes ) * Backup ring (included in 00)... * O-ring (included in 00) Piston cup Ram Compression spring Adapter disk... * O-ring (included in 00) Base... Latch Screw... 0 Blade pin... 0 Pivot pin Retaining clip Movable blade... 0 Ball... 0 Spring Screw... Fixed blade... Guide plate Latch... 0 Head... 0 Blade, fixed... 0 Blade, movable... 0 Screw... 0 Full head assembly kit (ESG-FHK)... (includes, 0,,,,, 0 ) 0 Conversion assembly kit (ESG-CK)... (includes,,,, 0 ) 0 Blade kit (ESG-BK) (includes )... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

24 Head and Ram Illustration and Parts List ESGLX * Head and ram (includes ) * O-ring (included in 00)... * Piston backup ring (included in 00)... Screw, Mx mm button hd cap (units without item ) Compression spring... Adapter disk... * O-ring (included in 00) Piston... Stationary blade... Cutting blade... 0 Screw... Snap ring... Cutting head... Cutting head base... Pin, x 0... Sleeve... Pin... Guide plate... Side plate... Pull pin... 0 Brace plate... Screw... 0 Stroke adjustor (used in models with Mx mm screw, key ) Screw, Mx mm socket hd cap (units with item )... 0 Plate kit (includes,,,, 0)... 0 Blade kit (includes,, )... 0 Fastener kit (includes,, 0,, -,..., -) Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

25 Head and Ram Illustration and Parts List ETSLX 0 Head and ram (includes ) 0000 Bushing with seal... 0 Cutter blade kit (includes ) Cutter plate... Cutting rod... Spring-type straight pin... Socket head cap screw, m Hex head cap screw, mx Compression spring Cutter head... * Seal bushing (included in 00)... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

26 Head and Ram Illustration and Parts List ETSLX 0 0 Head assembly (includes, ) 0 Cutter blade kit (includes )... Fixed blade... Movable blade... Roll pin... Socket head cap screw Hex head cap screw, mx Compression spring... Cutter head... * O-ring (included in 00)... * Piston backup ring (included in 00) Bushing Washer... Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

27 Head and Ram Illustration and Parts List LS00X 0A 0A, 0B Ø Groove for Identification. Cylinder with groove use 0B. Tools with serial no. 0MN000 and smaller use 0A 00 Punch head assembly (includes ) 00 Cylinder cap Cylinder cap cover Spring, 0 mm... Backup ring... O-ring, x mm (black) Piston... Screw, set hex socket (DIN M x )... Cylinder adapter... O-ring,. x mm (green)... 0A O-ring, x mm (green)... 0B O-ring,, x... 0 Cylinder... O-ring... Retaining ring Cover Pump block extension Seal kit (includes,,,, 0,, ) 0 Adapter kit (includes (),,,, ) Greenlee Tools, Inc. Boeing Dr. Rockford, IL 0- USA --00

28 Boeing Drive Rockford, IL 0- USA Greenlee Tools, Inc. An ISO 00 Company USA Tel: Fax: 00-- Canada Tel: Fax: 00-- International Tel: Fax: +---