SERVICE MANUAL (EK10L shown) GATOR Battery-powered In-line Tools 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 2076 REV 2011 Greenlee Textron Inc. 3/11
Battery-powered In-line Tools Table of Contents Safety... 2 Purpose of this Manual... 2 Other Publications... 2 Important Safety Information... 3 Main Illustrations All Tools... Main Parts List All Tools...6 7 Head and Ram Illustration and Parts List EK210L... 8 EK10L... 9 EK622L... 10 EK628L...11 13 ETS8L... 1 ETS12L... 1 ES32L, ES32FL, ES20L... 16 ESG2L... 17 LS0L... 18 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 Tools listed on this page. Keep this manual available to all personnel. Replacement manuals are available upon request at no charge at www.greenlee.com. Other Publications Operation Manuals EK210L 20766 EK10L 207663 EK622L 20766 EK628L 207662 ETS8L 207672 ETS12L 207671 ES32L 207668 ES32FL 20690 ES20L 206893 ESG2L 20689 LS0L 206896 Do not discard this product or throw away! For recycling information, go to www.greenlee.com. 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 Greenlee Textron Inc. KEEP THIS MANUAL Greenlee / A Textron Company 2 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line 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 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Main Illustrations All Tools 70 68 71 73 67 62 6 80 68 7 78 29 19 3 2 79 69 9 76 89 Motor Assembly 87 8 88 83 81 86 8 82 Greenlee / A Textron Company Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Main Illustrations All Tools (cont d) Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly 33 3 3 38 36 37 3 39 31 32 0 20 3 23 22 21 All tools except ESG2L 7 1 2 6 60 2 1 7 0 61 62 63 0 ESG2L 3 9 8 6 0 Greenlee / A Textron Company Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Main Parts List All Tools 20860 Relief lever kit (includes 2, 3) 2 Screw... 1 3 Relief valve lever... 1 20033 Control board (EK210L)... 1 20032 Control board (EK10L)... 1 20601 Control board (EK622L)... 1 20610 Control board (EK628L)... 1 20031 Control board (ETS8L, ETS12L, ES32L, ES32FL, ES20L, ESG2L)... 1 20699 Control board (LS0L)... 1 * Seal... 2 6 20920 Sensor (EK210L, EK10L, EK622L, EK628L)... 1 0121839 Screw (ETS8L, ETS12L, ES32L, ES32FL, ES20L, ESG2L, LS0L)... 1 19 0018990 Piston pump assembly (includes 20 23)... 1 20 Piston pump... 1 21 Spring... 1 22 0019309 Piston pump housing... 1 23* Piston seal... 1 29 0018922 Relief valve unit (includes 31 39) (all except EK622L, ESG2L) ETS12L, LS0L)... 1 20799 Relief valve unit (includes 31 39) (EK622L, ESG2L, ETS12L, LS0L)... 1 31 0019 Valve seat... 1 32 Needle valve... 1 33 Plunger... 1 3 Spring... 1 3 Lock washer (all except EK622L, ESG2L, ETS12L, LS0L)... 2 Lock washer (EK622L, ESG2L, ETS12L, LS0L)... 6 36* O-ring... 1 37* O-ring... 1 38 Pressure relief... 1 39 Screw... 1 9 208120 Pump housing unit (includes 0 7) (EK210L, EK628L, ETS8L, ES32L, ES32FL, ES20L)... 1 20796 Pump housing unit (includes 0 7) (EK10L, ETS12L)... 1 2079 Pump housing unit (includes 0 7) (EK622L)... 1 207116 Pump housing unit (includes 0 63) (ESG2L)... 1 20693 Pump housing unit (includes 0 7) (LS0L) 0 20861 Clamp, 10 pack... 1 0* Clamp... 2 1 Screw... 1 2 Threaded bushing... 1 3 Pump block... 1 Threaded bushing... 1 Screen... 1 6 209296 Reservoir... 1 7* O-ring... 1 8 Washer... 1 9 Threaded bushing... 1 60 Valve seat... 1 61 Spring... 1 62 Washer... 1 63 Needle valve... 1 68 20797 Housing unit (includes 69 79) (all except ETS8L)... 1 20081 Housing unit (includes 70 78) (ETS8L)... 1 69 Ring (ETS8L)... 1 70 Screw... 71 Screw... 2 72 Compression spring, DA. x L1.0... 1 73 Trigger link... 1 7 Housing half... 1 76 Housing half... 1 77 Relief valve button... 1 78 Trigger cover... 1 79 Stud (ETS8L)... 1 80 208132 Motor assembly (includes 81 89)... 1 81 Retaining ring... 1 82 001989 Pin... 1 83 Motor cap... 1 8 Disc housing... 1 8 Disc... 2 86 Screw... 2 87 Gear lube, 1. g... 1 88 Motor adapter... 1 89 Electric motor... 1 Greenlee / A Textron Company 6 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Main Parts List All Tools (cont d) 20837 Decal kit, crimper... 1 20838 Decal kit, cutter... 1 207632 Identification decal (EK210L)... 1 207631 Identification decal (EK10L)... 1 207633 Identification decal (EK622L)... 1 207630 Identification decal (EK628L)... 1 20762 Identification decal (ETS8L)... 1 20761 Identification decal (ETS12L)... 1 207637 Identification decal (ES32L)... 1 20688 Identification decal (ES32FL)... 1 206913 Identification decal (ES20L)... 1 20691 Identification decal (ESG2L)... 1 206916 Identification decal (LS0L)... 1 00807 Carrying strap 200 Carrying case 207023 Carrying case (LS0L) 20769 Connector compatibility decal (EK10L) 20768 Connector compatibility decal (EK622L) 20767 Connector compatibility decal (EK628L) * 00797 Seal kit (includes items marked with an asterisk, bushings not included) 209190 18 V battery 1. Ah 209189 18 V battery 3.0 Ah 209201 18 V charger 120 VAC 209202 18 V charger 230 VAC 20920 18 V charger 12 VDC 207087 18 V corded adapter 120 VAC 207088 18 V corded adapter 230 VAC 20992 Li (18 V) to NiCd, NiMH (12 V) charger adapter 207878 Biodegradable hydraulic fluid Greenlee / A Textron Company 7 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Head and Ram Illustration and Parts List EK210L Battery-powered In-line Tools 11 12 10 1 2 3 9 7 6 8 1 012000 Bushing with seal... 1 20862 Die holder kit (includes 2 6, 9, 10) 2 Shoulder bolt... 1 3 Cap... 1 Compression spring... 1 Compression spring... 1 6 Washer... 1 7 20011 Crimping head... 1 8 001929 Screw... 1 9 0019716 Screw... 2 10 Die holder... 1 11 0019708 Pinch hazard decal... 1 12* Seal bushing (included in 00797)... 1 Greenlee / A Textron Company 8 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Head and Ram Illustration and Parts List EK10L Battery-powered In-line Tools 16 17 1 2 3 1 7 6 1 8 13 11 10 12 9 1* O-ring (included in 00797)... 1 2* Piston backup ring (included in 00797)... 1 3 0019082 Bushing... 1 0018981 Head unit (includes 16) 20863 Ram kit (includes 6, 1, 1) Shoulder bolt... 1 Disc... 1 6 Spring... 1 7 0019180 Fixed head... 1 2086 Hardware kit (includes 8 11, 13, 1) 8 Screw... 1 9 Retaining ring... 10 Pin... 2 11 Spring... 2 20099 Head and latch kit (includes 12, 16) 12 Movable head... 1 13 Screw... 1 1 Pin... 1 1 Ram adapter... 1 16 Latch head... 1 17 0019708 Pinch hazard decal... 1 Greenlee / A Textron Company 9 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Head and Ram Illustration and Parts List EK622L Battery-powered In-line Tools 2 1 17 2 9 1 3 17 7 6 8 1 19 11 12 7 21 22 13 19 11 10 20 21 18 16 18 23 2 11 22 17 12 17 1* O-ring (included in 00797)... 1 2* Backup ring (included in 00797)... 1 3 20797 Ram... 1 008371 Adapter disk... 1 * O-ring (included in 00797)... 1 6 008398 Compression spring... 1 20866 Pin kit (includes 7 9, 17) 7 Spring... 2 8 Pin... 1 9 Pin... 1 20867 Die retainer kit (includes 10, 11, 18 22) 10 Die retainer... 2 11 Compression spring... 12 001681 Screw... 2 13 00830 Bottom crimp head... 1 1 0121693 Latch... 1 1 0121731 Top die holder... 1 16 012171 Bottom die holder... 1 17 Retaining ring... 18 Die release button... 2 19 Die retainer... 2 20 Roll Pin... 2 21 Die release button... 2 22 Locking pin... 2 2086 Die holder kit (includes 23, 2) 23 Threaded stud... 1 2 Pin... 1 2 202068 Piston cup... 1 Greenlee / A Textron Company 10 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Ram Illustration and Parts List EK628L 1 1 16 2 3 6 8 7 1 9 11 12 10 13 208133 Ram unit (includes 1 1)... 1 20797 Jaw holder kit (includes 1, 7, 8) 1 209292 Sheath... 1 209399 Spring kit (includes 2 6) 2 Shoulder bolt... 1 3 Disc... 1 Compression spring... 1 Washer... 1 6* O-ring (included in 00797)... 1 7 20796 Screw... 1 8 Jaw holder... 1 20900 Latch kit (includes 9 12) 9 Compression spring... 1 10 Locking pin... 1 11 Compression spring... 1 12 Pin... 1 20901 Roller kit (includes 13, 1) 13 Roller... 2 1 Ram... 1 1 012000 Bushing with seal... 1 16* Seal bushing (included in 00797)... 1 Greenlee / A Textron Company 11 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Crimping Jaw Units Illustration and Parts List EK628L 130 129 CJ22 CJXPJ 12C 12 122 12B 12 127 128 123 122 123 129 130 CJB 12A 202683 CJ22 crimping jaw unit for cul and UL classified crimps 20269 CJXPJ crimping jaw unit (includes 122-12) 20268 CJB single-use lock cutter (includes 122-126) 20902 Jaw pivot kit (includes 122, 123) 122 Retaining ring... 2 123 Pivot pin... 1 12A Jaw, sharp CJB... 1 12B Jaw, CJXPJ... 2 12C Jaw, CJ22... 2 12 2022 Extension spring... 1 126 Jaw, flat CJB... 1 2023623 Die retaining pin kit (includes 127 130) 127 Die retaining pin... 2 128 Compression spring... 2 129 Release button... 2 130 Retaining ring... 2 122 123 12 126 Greenlee / A Textron Company 12 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Illustration and Parts List Optional Accessories EK628L Battery-powered In-line Tools CJD3BG CJD3O CJD3 118A 118A 118C 110A 111 110C 111 110D 111 113 11 113 11 11 113 11 113 118A 116 117 11 11 116 117 118A 116 117 118C 117 119 120 113 121 glued in with Loctite 270 (green) 116 11 118B 11 120 119 CJK Kearney 11 116 117 111 110B 118B 2027121 CJD3BG crimping jaw unit (includes 110 118) 2027122 CJD3O crimping jaw unit (includes 110 118) 202068 CJD3 crimping jaw unit (includes 110 118) 202011 CJK Kearney crimping jaw unit (includes 110 118, 119-121) 110A Jaw, CJD3BG... 2 110B Jaw, CJK... 2 110C Jaw, CJD3O... 2 110D Jaw, CJD3... 2 111 2022 Extension spring... 1 20902 Jaw pivot kit (includes 113, 11) 113 Retaining ring... 2 11 Pin pivot... 1 11 Bushing... 2 116 Compression spring... 2 117 Lock adapter... 2 118A 20212 Jaw covers, CJD3O/CJD3BG (set of 2)... 1 118B 2022386 Jaw covers, CJK (set of 2)... 1 118C 2021086 Jaw covers, CJD3 (set of 2)... 1 119 Bushing... 2 120 Ball, 3 mm... 2 121 Locking pin... 1 010370 Die pin kit, W -style dies (includes 11 117) 010108 Die pin kit, Kearney-style dies (includes 116, 119 121) Greenlee / A Textron Company 13 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Head and Ram Illustration and Parts List ETS8L Battery-powered In-line Tools 3 9 7 10 2 1 6 8 1 012000 Bushing with seal... 1 2026 Cutter blade kit (includes 2 ) 2 Cutter plate... 1 3 Cutting rod... 1 Spring-type straight pin... 1 Socket head cap screw, m-1... 1 6 001929 Hex head cap screw, m3x... 1 7 0019120 Compression spring... 1 8 2026760 Cutter head... 1 9 2026 Pinch hazard decal... 1 10* Seal bushing (included in 00797)... 1 Greenlee / A Textron Company 1 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Head and Ram Illustration and Parts List ETS12L Battery-powered In-line Tools 11 8 9 1 3 2 10 6 7 2033626 Head assembly (includes 1 7) 2033628 Cutter blade kit (includes 1 )... 1 1 Fixed blade... 1 2 Movable blade... 1 3 Roll pin... 1 Socket head cap screw... 1 001929 Hex head cap screw, m3x... 1 6 0019236 Compression spring... 1 7 Cutter head... 1 8* O-ring (included in 00797)... 1 9* Piston backup ring (included in 00797)... 1 10 0019082 Bushing... 1 11 2026 Pinch hazard decal... 1 Greenlee / A Textron Company 1 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Head and Ram Illustration and Parts List ES32L, ES32FL, and ES20L 16 18 1 ES32FL 7 2 1 1 11 10 6 3 17 ES20L 8 9 ES32L 12 13 0121197 Head unit assembly, ES32L (includes 1 1) 20687 Head unit assembly, ES32FL (includes 1 1) 207273 Head unit assembly, ES20L (includes 1 1) 20868 Ram kit (includes 1 3, ) 1 Piston... 1 2 Coil spring... 1 3 Steel washer... 1 20870 Hardware kit (includes, 8 11, 13, 1) Retaining clip... 2 Steel washer... 1 6 001929 Screw... 1 7 0120913 Aluminum head... 1 8 Screw... 1 9 Pivot... 1 10 Retaining clip... 1 11 Pivot... 1 20869 Blade kit, ES32L (includes 12 1) 20689 Blade kit, ES32FL (includes 12 1) 207271 Blade kit, ES20L (includes 12 1) 12 Fixed blade... 1 13 Pivot bolt... 1 1 Movable blade... 1 1 Hex nut... 1 16 012000 Bushing with seal... 1 17 202832 Pinch hazard decal... 1 18* Seal bushing (included in 00797)... 1 Greenlee / A Textron Company 16 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Head and Ram Illustration and Parts List ESG2L Battery-powered In-line Tools 3 2 1 9 17 1 16 1 8 7 6 10 11 18 12 13 19 207103 Head assembly (includes 1 19) 1* Backup ring (included in 00797)... 1 2* O-ring (included in 00797)... 1 3 202068 Piston cup... 1 207107 Ram... 1 Compression spring... 1 6 Adapter disk... 1 7* O-ring (included in 00797)... 1 8 207109 Base... 1 9 207108 Latch... 1 10 207106 Screw... 1 11 207111 Blade pin... 1 12 20711 Pivot pin... 2 13 Retaining clip... 1 20710 Movable blade... 1 1 20711 Ball... 1 16 207113 Spring... 1 17 207112 Screw... 18 20710 Fixed blade... 1 19 207110 Guide plate... 1 Greenlee / A Textron Company 17 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Head and Ram Illustration and Parts List LS0L Battery-powered In-line Tools 13 12 11 10 9 7 6 8 3 1 2 20698 Punch head assembly (includes 1 13) 1 206937 End cap... 1 2 Spring disc... 1 3 00828 Compression spring... 1 Backup ring... 1 Seal... 1 6 20691 Ram... 1 7 20692 Ram housing... 1 8 Seal... 1 9 O-ring... 1 10 2069 Swivel... 1 11 Washer... 2 12 20697 Pump block extension... 1 13 Retaining ring... 1 207708 Ring kit (includes 2,,, 8, 9, 11, 13) Greenlee / A Textron Company 18 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Battery-powered In-line Tools Greenlee / A Textron Company 19 Boeing Dr. Rockford, IL 61109-2988 USA 81-397-7070
Boeing Drive Rockford, IL 61109-2988 USA 81-397-7070 An ISO 9001 Company Greenlee Textron Inc. is a subsidiary of Textron Inc. www.greenlee.com USA Tel: 800-3-0786 Fax: 800-1-2632 Canada Tel: 800-3-0786 Fax: 800-2-283 International Tel: +1-81-397-7070 Fax: +1-81-397-927