GATOR Battery-powered In-line X Tools

Transcription

1 SERVICE MANUAL (EK2LX 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 Greenlee Textron Inc. 3/1

2 Battery-powered In-line X Tools Table of Contents Safety... 2 Purpose of this Manual... 2 Other Publications... 2 Important Safety Information... 3 Main Illustrations All Tools... 6 Main Parts List All Tools... 8 Head and Ram Illustrations and Parts Lists EK6IDL... 9 EK10L EK2L, EK628L EK622L... 1 ES20L, ES32L, ES32FL... 1 ESC3L ESG2L... 1 ESGL ETS8L ETS12L LS 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 Battery-powered In-line X Tools 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 EK6IDLX EK10LX EK2LX EK622LX EK628LX ES20LX ES32LX ES32FLX ESC3LX ESG2LX ESGLX ETS8LX ETS12LX LS100X 2092 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 Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products. GATOR is a registered trademark of Textron Innovations Inc. KEEP THIS MANUAL Greenlee / A Textron Company 2 Boeing Dr. Rockford, IL USA

3 Battery-powered In-line X Tools 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 / A Textron Company 3 Boeing Dr. Rockford, IL USA

4 Battery-powered In-line X Tools Main Illustrations All Tools 101 All housing screws screwed in completely. T=2. Nm max Screw on hand-tight. Then turn out until the radial hole is free to screw in the anti-twist screw. T=1 Nm T=0 Nm 80 2 T=12 Nm max T=2 Nm 0 T=2 Nm max. 29 T=12 Nm 69 9 T=1 Nm Motor Assembly Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

5 Battery-powered In-line X Tools Main Illustrations All Tools (cont d) Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly All tools except EK6IDL, ESC3L, ESG2L, ESGL, and LS100X 3 0 T=12 Nm T=1 Nm T=12 Nm T=. Nm 2 T=12 Nm 6 T=8 Nm EK6IDL, ESC3L, and ESG2L T=. Nm 6 0 Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

6 Battery-powered In-line X Tools Main Illustrations All Tools (cont d) Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly ESGL and LS100X T=12 Nm T=1 Nm 26 T=0. Nm T=0. Nm 0 2 T=12 Nm 6 T= Nm T=2 Nm 6 6 T=. Nm 0 Greenlee / A Textron Company 6 Boeing Dr. Rockford, IL USA

7 Battery-powered In-line X Tools Main Parts List All Tools Relief lever kit (includes 2, 3) 2 Screw Relief valve lever Control board (X version) Control Board (EK2LX, EK628LX) Control Board (EK10LX) Control Board (EK622LX) Control Board (EK6IDLX) Control Board (ETS8LX, ETS12LX) Control Board (ES32LX, ES32FLX,... ES20LX, ESG2LX) Control Board (ESGLX) Control Board (ESC3LX) Control board (LS100X) Display Screen (LS100X)... 1 * Seal Sensor (EK6IDL, EK10L, EK2L, EK622L, EK628L, LS100X) Screw (cutters) Ring (EK6IDL, EK10L, EK622L, ESC3L, ESG2L, ESGL, ETS12L) Ring (EK2L, EK628L, ETS8L) Ring (ES20L, ES32L, ES32FL, LS100X) Piston pump assembly (includes 20 26) Piston pump Spring Piston pump housing * Piston seal * Felt seal Screw Spring Relief valve unit (includes 31 39) (all except EK6IDL, EK622L, ESC3L, ESG2L, ESGL, ETS12L, LS100X) Relief valve unit (includes 31 39) (EK6IDL, EK622L, ETS12L) Relief valve unit (includes 31 39) (ESC3L, ESG2L) Relief valve unit (includes 31 39) (ESGL, LS100X) Valve seat Needle valve Plunger Spring Washer... 36* O-ring * O-ring Pressure relief Screw Pump housing unit (includes 2, 0 63) (EK6IDL, ESC3L, ESG2L) Pump housing unit (includes 2, 0 ) (EK10L, ETS12L) Pump housing unit (includes 2, 0 ) (EK2L, EK628L, ETS8L) Pump housing unit (includes 2, 0 ) (EK622L) Pump housing unit (includes 2, 0 63) (ES20L, ES32L, ES32FL) Pump housing unit (includes 2, 1, 6 6) (ESGL) Pump housing unit (includes 2, 1, 6 6) (LS100X) Ball Screw Shaft... 1 Bushing... 2 Bearing O-ring... 1 Plate Screw Solenoid Clamp, nylon, 10 pack * Clamp Screw Threaded bushing Pump block Threaded bushing Screen Reservoir (all except ESGL, LS100X) Reservoir (ESGL, LS100X)... 1 * O-ring Washer Threaded bushing Valve kit (includes 60 63) 60 Valve seat Spring Washer Needle valve Spring Washer Screw... 1 Greenlee / A Textron Company Boeing Dr. Rockford, IL USA

8 Battery-powered In-line X Tools Main Parts List All Tools (cont d) 6 Top Housing unit (includes 69 9) (all except LS100X) Housing unit (includes 0 8) (LS100X) Ring Screw Screw Compression spring, DA. x L Trigger link... 1 Housing half Housing half... 1 Relief valve button Trigger cover Stud Motor assembly (includes 81 89) Retaining ring Pin Motor cap Disc housing Disc Screw Gear lube, 1. g Motor adapter Electric motor In-line GATOR decal In-line Intelli-PUNCH decal Identification decal (ETS8LX) Identification decal (ETS12LX) Identification decal (LS100X) Warning decal, crimping tool Warning decal, cutter Carrying strap Carrying case (ALL OTHERS) Carrying case (ESGL) Carrying case (LS100X) Carrying pouch(ek2l) Connector compatibility decal (EK6IDL) 2069 Connector compatibility decal (EK10L) 2060 Connector compatibility tag (EK2L) Connector compatibility decal (EK622L,... EK628L) * 009 Seal kit (includes items marked with an asterisk, bushings not included) V battery 2.0 Ah V battery.0 Ah V charger 120 VAC V charger 230 VAC V charger 12 VDC V corded adapter 120 VAC V corded adapter 230 VAC 2088 Biodegradable hydraulic fluid FCC X version decal Identification decal (EK6IDLX) Identification decal (EK10LX) Identification decal (EK2LX) Identification decal (EK622LX) Identification decal (EK628LX) Identification decal (ES20LX) Identification decal (ES32LX) Identification decal (ES32FLX) Identification decal (ESC3LX) Identification decal (ESG2LX) Identification decal (ESGLX)... 1 Greenlee / A Textron Company 8 Boeing Dr. Rockford, IL USA

9 Head and Ram Illustration and Parts List EK6IDL Battery-powered In-line X Tools T=2 Nm T=2 Nm Head and ram (includes 1 21) Fixed head Head and latch kit (includes 2, 3) 2 Movable head Latch head Fastener kit (includes ) Pin... 2 Retaining ring... 6 Spring... 2 Screw Cone die Ram kit (includes 9 13) 9 Ram Sleeve Piston cup, small Bushing Adapter disk Spring kit (includes 1, 1) 1 Compression spring Spring Hex screw, M x * O-ring (included in 009) * Piston backup ring (included in 009) * O-ring, 28.1 x 3.3 N80 (included in 009) * Backup ring (included in 009) * O-ring (included in 009)... 1 Greenlee / A Textron Company 9 Boeing Dr. Rockford, IL USA

10 Head and Ram Illustration and Parts List EK10L Battery-powered In-line X Tools T=2 Nm T=2 Nm Head and ram (includes 18) Ram kit (includes 6, 1, 1, 18) Shoulder bolt... 1 Disc Spring Fixed head Hardware kit (includes 8 11, 13, 1) 8 Screw Retaining ring Pin Spring Head and latch kit (includes 12, 16) 12 Movable head Screw Pin Ram adapter Latch head Washer * O-ring (included in 009) * Piston backup ring (included in 009) Bushing... 1 Greenlee / A Textron Company 10 Boeing Dr. Rockford, IL USA

11 Ram Illustration and Parts List EK2L and EK628L Battery-powered In-line X Tools T=2 Nm Ram unit (includes 1 1) Sheath Spring kit (includes 2 6) 2 Shoulder bolt Disc... 1 Compression spring... 1 Washer * O-ring (included in 009) Screw Jaw holder Latch kit (includes 9 12) 9 Compression spring Locking pin Compression spring Pin Roller kit (includes 13, 1) 13 Roller Ram Bushing with seal * Seal bushing (included in 009)... 1 Greenlee / A Textron Company 11 Boeing Dr. Rockford, IL USA

12 Battery-powered In-line X Tools Jaw Units Illustration and Parts List CJ22 CJXPJ 12C B CJB 12A CJ22 crimping jaw unit for cul and UL classified crimps CJXPJ crimping jaw unit (includes ) CJB single-use lock cutter (includes ) Jaw pivot kit (includes 122, 123) 122 Retaining ring Pivot pin A Jaw, sharp CJB B Jaw, CJXPJ C Jaw, CJ Extension spring Jaw, flat CJB Die retaining pin kit (includes ) 12 Die retaining pin Compression spring Release button Retaining ring Greenlee / A Textron Company 12 Boeing Dr. Rockford, IL USA

13 Battery-powered In-line X Tools Jaw Units Illustration and Parts List (cont d) CJD3BG CJD3O CJD3 118A 118A 118C 110A C D A A C glued in with Loctite 20 (green) B CJK Kearney B 118B CJD3BG crimping jaw unit (includes ) CJD3O crimping jaw unit (includes ) CJD3 crimping jaw unit (includes ) CJK Kearney crimping jaw unit (includes , ) 110A Jaw, CJD3BG B Jaw, CJK C Jaw, CJD3O D Jaw, CJD Extension spring Jaw pivot kit (includes 113, 11) 113 Retaining ring Pin pivot Bushing Compression spring Lock adapter A Jaw covers, CJD3O/CJD3BG (set of 2) B Jaw covers, CJK (set of 2) C Jaw covers, CJD3 (set of 2) Bushing Ball, 3 mm Locking pin Die pin kit, W -style dies (includes 11 11) Die pin kit, Kearney-style dies (includes 116, ) Greenlee / A Textron Company 13 Boeing Dr. Rockford, IL USA

14 Head and Ram Illustration and Parts List EK622L Battery-powered In-line X Tools T=2 Nm T=2 Nm Head and ram (includes 3 2) Ram Adapter disk... 2 * O-ring (included in 009) Compression spring Pin kit (includes 9, 1) Spring Pin Pin Die retainer kit (includes 10, 11, 18 22) 10 Die retainer Compression spring Screw Bottom crimp head Latch Top die holder Bottom die holder Retaining ring Die release button Die retainer Roll Pin Die release button Locking pin Die holder kit (includes 23, 2) 23 Threaded stud Pin Piston cup * Backup ring (included in 009) * O-ring (included in 009)... 1 Greenlee / A Textron Company 1 Boeing Dr. Rockford, IL USA

15 Battery-powered In-line X Tools Head and Ram Illustration and Parts List ES20L, ES32L, and ES32FL ES20L 8 9 ES32L ES32FL Head assembly, ES20L (includes 1 1) Head assembly, ES32L (includes 1 1) 2068 Head assembly, ES32FL (includes 1 1) Ram kit (includes 1 3, ) 1 Piston Coil spring Steel washer Hardware kit (includes, 8 11, 13, 1) Retaining clip... 2 Steel washer Screw Aluminum head Screw Pivot Retaining clip Pivot Blade kit, ES32L (includes 12 1) Blade kit, ES32FL (includes 12 1) 2021 Blade kit, ES20L (includes 12 1) 12 Fixed blade Pivot bolt Movable blade Hex nut Bushing with seal * Seal bushing (included in 009)... 1 Greenlee / A Textron Company 1 Boeing Dr. Rockford, IL USA

16 Head and Ram Illustration and Parts List ESC3L Battery-powered In-line X Tools T=. Nm T=2. Nm T=2. Nm Head assembly (includes 20) 1* Backup ring (included in 009) * O-ring (included in 009) Piston cup Screw Piston rod Spring Shim O-ring Base Screw Block Link Pin Ring Blade Pivot pin Nut Cover Screw Screw... 2 Greenlee / A Textron Company 16 Boeing Dr. Rockford, IL USA

17 Head and Ram Illustration and Parts List ESG2L Battery-powered In-line X Tools T=2 Nm Head assembly (includes 19) 1* Backup ring (included in 009) * O-ring (included in 009) Piston cup Ram... 1 Compression spring Adapter disk... 1 * O-ring (included in 009) Base Latch Screw Blade pin Pivot pin Retaining clip Movable blade Ball Spring Screw Fixed blade Guide plate... 1 Greenlee / A Textron Company 1 Boeing Dr. Rockford, IL USA

18 Head and Ram Illustration and Parts List ESGL Battery-powered In-line X Tools * Head and ram (includes 8 21) 1 O-ring (included in 20906) Piston backup ring (included in 20906) Screw, M3x6 mm button hd cap (units without item 22)... 2 * Screw, M3x mm socket hd cap (units with item 22) Compression spring... 2 Adapter disk O-ring (included in 20906) Piston Stationary blade Cutting blade Screw Snap ring Cutting head Cutting head base Pin, 8 x Sleeve Pin Guide plate Side plate Pull pin Brace plate Screw Stroke adjustor (used in models with M3x mm screw) Plate kit (includes 12, 13, 1, 18, 20) Blade kit (includes 8, 9, 1) Fastener kit (includes 3,, 10, 11, 1-16,... 19, 21) Greenlee / A Textron Company 18 Boeing Dr. Rockford, IL USA

19 Head and Ram Illustration and Parts List ETS8L Battery-powered In-line X Tools Head and ram (includes 2 8) Bushing with seal Cutter blade kit (includes 2 ) 2 Cutter plate Cutting rod... 1 Spring-type straight pin... 1 Socket head cap screw, m Hex head cap screw, m3x Compression spring Cutter head * Seal bushing (included in 009)... 1 Greenlee / A Textron Company 19 Boeing Dr. Rockford, IL USA

20 Head and Ram Illustration and Parts List ETS12L Battery-powered In-line X Tools Head assembly (includes 1, 11) Cutter blade kit (includes 1 ) Fixed blade Movable blade Roll pin... 1 Socket head cap screw Hex head cap screw, m3x Compression spring... 1 Cutter head * O-ring (included in 009) * Piston backup ring (included in 009) Bushing Washer... 1 Greenlee / A Textron Company 20 Boeing Dr. Rockford, IL USA

21 Head and Ram Illustration and Parts List LS100X Battery-powered In-line X Tools Punch head assembly (includes 1 12) Cylinder cap Cylinder cap cover Spring, 0 mm... 1 Backup ring... 1 O-ring, x 3 mm (black) Piston... 1 Screw, set hex socket (DIN 916 M x ) Cylinder adapter O-ring, 6. x 2 mm (green) O-ring, 26 x 2 mm (green) Cylinder O-ring Retaining ring Cover Pump block extension Seal kit (includes,,, 9, 10, 12, 13) Adapter kit (includes 8, 9, 12, 13) Greenlee / A Textron Company 21 Boeing Dr. Rockford, IL USA

22 Battery-powered In-line X Tools Greenlee / A Textron Company 22 Boeing Dr. Rockford, IL USA

23 Battery-powered In-line X Tools Greenlee / A Textron Company 23 Boeing Dr. Rockford, IL USA

24 Boeing Drive Rockford, IL USA An ISO 9001 Company Greenlee Textron Inc. is a subsidiary of Textron Inc. USA Tel: Fax: Canada Tel: Fax: International Tel: Fax: