Greenlee Gator EK410L Battery Powered Crimper User manual

Brand: Greenlee

Model: Gator EK410L Battery Powered Crimper

Category: Power tools

Type: User manual

Greenlee Gator EK410L Battery Powered Crimper is a hand-held self-contained crimping tool, intended to crimp copper and aluminum cables and is compatible with KC4-type dies. The crimper has a maximum force of 4 tons and creates a crimp that is durable and reliable. It is powered by a 9.6V battery which can make approximately 85 crimps on a single charge. The crimper has an LED display and a relief valve which sounds after every completed crimp, It takes approximately 45 minutes to fully charge the battery.

INSTRUCTION MANUAL

GATOR

EK410

Battery-powered

Crimping Tool

Serialnummer

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Greenlee / A Textron Company 2 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Allspecicationsarenominalandmaychangeasdesignimprove-

ments 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.

BlackburnisaregisteredtrademarkofThomas&Betts.

TellusisaregisteredtrademarkofShellOilCompany.

KEEP THIS MANUAL

Table of Contents

Description ..................................................................... 2

Safety ............................................................................. 2

Purpose of this Manual .................................................. 2

Important Safety Information ..................................... 3–4

Identication ................................................................... 5

Specications ................................................................. 5

Operation .................................................................... 6–7

Die Selection .................................................................. 8

ConnectorSelection ....................................................... 8

Maintenance ................................................................... 9

Troubleshooting .............................................................. 9

Illustrations ............................................................. 10–11

PartsList ...................................................................... 12

Description

TheEK410Battery-poweredCrimpingToolisa

hand-held,self-containedcrimpingtoolintendedto

crimpcopperandaluminumcablewithKC4-typedies.

Safety

Safety is essential in the use and maintenance of Green-

lee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allpersonnelwith

the safe operation and maintenance procedures for the

followingGreenleetool:

 EK410Battery-poweredCrimpingTool

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

chargeatwww.greenlee.com.

Greenlee / A Textron Company 3 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

IMPORTANT SAFETY INFORMATION

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,

denedbelow,indicatestheseverityofthehazard.

Themessageafterthesignalwordprovidesinfor-

mation for preventing or avoiding the hazard.

Hazardsorunsafepracticeswhich,ifnotavoided,

MAYresultininjuryorpropertydamage.

Hazardswhich,ifnotavoided,COULDresultin

severe injury or death.

Immediatehazardswhich,ifnotavoided,WILL

result in severe injury or death.

SAFETY

ALERT

SYMBOL

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Failuretoobservethiswarning

could result in severe injury or death.

Skininjectionhazard:

Donotusehandstocheckfor

oilleaks.Highpressureoileasily

puncturesskincausingserious

injury,gangrene,ordeath.Ifinjured,

seekmedicalhelpimmediatelyto

remove oil.

Weareyeprotectionwhenoperating

or servicing this tool.

Failuretoweareyeprotectioncould

result in serious eye injury from

ying debris or hydraulic oil.

Do not use solvents or ammable

liquids to clean the crimping tool.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

Anincompletecrimpcancauseare.

• Useproperdie,connector,andcablecombina-

tions. Improper combinations can result in an

incomplete crimp.

• Thereliefvalvewillsoundtoindicatea

completed crimp. If you do not hear the sound of

thereliefvalve,thecrimpisnotcomplete.

Failuretoobservethesewarningscouldresultin

severe injury or death.

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could

result in severe injury or death.

Greenlee / A Textron Company 4 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

IMPORTANT SAFETY INFORMATION

Note: Keep all decals clean and legible, and replace

when necessary.

Pinchpoints:

• Removebatterybeforechanging

dies,adapters,orjaws.

• Keephandsawayfromthecrimp-

ingtoolheadwhencrimping.

Failuretoobservethesewarnings

could result in severe injury or death.

Donotdisposeofbatteriesinare.Theywillvent

fumes and may explode.

Failuretoobservethiswarningcouldresultinsevere

injury from harmful fumes or burns from ying

debris.

Inspect tool and dies before use. Replace any

wornordamagedparts.Adamagedorimproperly

assembledtoolcanbreakandstrikenearbyperson-

nel.

Failuretoobservethiswarningcouldresultinsevere

injury or death.

• Donotoperatethetoolwithoutdies.Damageto

the ram or crimping head can result.

• Donotoperatewiththecrimpingheadopen.

Damage to the ram or seals can result.

• Thistoolisnotdesignedforcontinuoususe.

After100crimpingcycles,allowthecrimping

tool to cool for 15 minutes.

• Donotplacethetoolinavise.Thecrimpingtool

isdesignedforhand-heldoperation.

• Thistoolmaybeusedindamporwetenviron-

ments;however,werecommendair-dryingthe

toolbeforeuseifitbecomessoaked.

• Usethistoolforthemanufacturer’sintended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

Donotallowanythingtocontactthebattery

terminals.

• Donotimmersethebatteriesinliquid.Liquid

may create a short circuit and damage the

battery.Ifbatteriesareimmersed,contactyour

service center for proper handling.

• Donotplacethebatteryintoapocket,tool

pouch,ortoolboxwithconductiveobjects.

Conductiveobjectsmaycreateashortcircuit

and damage the battery.

• Donotplaceabatteryonmoistgroundor

grass. Moisture may create a short circuit and

damage the battery.

Failure to observe these precautions may result in

injury or property damage.

• Donotstorethebatteryatmorethan60°C

(140°F).Damagetothebatterycanresult.

• Donotuseanothermanufacturer’scharger.

Othermanufacturers’chargersmayovercharge

and damage the battery.

• Donotattempttoopenthebattery.Itcontains

nouser-serviceableparts.

Failure to observe these precautions may result in

injury or property damage.

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.

Greenlee / A Textron Company 5 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

IdentiﬁcationIdentiﬁcation

Speciﬁcations

1. CrimpingDies

2. CrimpingHead

3. RetractButton

4. BatteryLock

5. BatteryCartridge

6. Trigger

7. Latch

8. LEDDisplay

CrimpingTool

 Length .................................................................................................. 356mm(14")

 Width ................................................................................................. 60mm(2-3/8")

Depth ................................................................................................ 80mm(3-1/8")

 Mass/Weight(withbattery)...................................................................1.6kg(3.5lb)

 SoundLevel .............................................................................. 75dB(A)at1meter

Vibration .................................................................................................... < 2.5 m/s

 HydraulicOil ................................................................................... Shell Tellus

T 15

CrimpingCapacities

 CrimpingForce ................................................................................... 35kN(4tons)

 AverageCrimpingTime .............................................................................4 seconds

 AverageCrimpsperCharge ...........................................................approximately85

Battery

 ChargingVoltage ............................................................................................... 9.6V

 ChargingTime .................................................................................................45 min

Greenlee / A Textron Company 6 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Operation

• Donotoperatethetoolwithoutdies.Damageto

the ram or crimping head can result.

• Donotoperatewiththecrimpingheadopen.

Damage to the ram or seals can result.

• Thistoolisnotdesignedforcontinuoususe.

After100crimpingcycles,allowthecrimping

tool to cool for 15 minutes.

• Donotplacethetoolinavise.Thecrimpingtool

isdesignedforhand-heldoperation.

• Thistoolmaybeusedindamporwetenviron-

ments;however,werecommendair-dryingthe

toolbeforeuseifitbecomessoaked.

• Usethistoolforthemanufacturer’sintended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

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could

result in severe injury or death.

Weareyeprotectionwhenoperating

or servicing this tool.

Failuretoweareyeprotectioncould

result in serious eye injury from

ying debris or hydraulic oil.

Pinchpoints:

• Removebatterybeforechanging

dies,adapters,orjaws.

• Keephandsawayfromthecrimp-

ingtoolheadwhencrimping.

Failuretoobservethesewarnings

could result in severe injury or death.

Greenlee / A Textron Company 7 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Operation(cont’d)

Charging the Battery

Readtheinstructionssuppliedwiththebatterycharger.

LED Display

Thistoolisequippedwithaspecialcircuitboardincor-

porating several important features to inform the user

aboutthecurrectstatusoftheunit.TheLEDsignalsin

thefollowingcases:

Crimping Cable

1. Pressthelockingangeandopenthecrimping

head.

2. Insert the properly assembled connector into the

crimping head.

3. Closethecrimpinghead.

4. Pullthetriggertomakethecrimp.

5. Holdthetriggerdownuntilthecrimpingtool

achievespressurerelief,whichisaccompaniedby

an audible “pop”.

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.

Note: If it is necessary to retract the ram before a crimp-

ing cycle is completed, push the retract button. Pushing

the retract button will result in the complete retraction of

the ram.

Anincompletecrimpcancauseare.

• Useproperdie,connector,andcablecombina-

tions. Improper combinations can result in an

incomplete crimp.

• Thereliefvalvewillsoundtoindicatea

completed crimp. If you do not hear the sound of

thereliefvalve,thecrimpisnotcomplete.

Failuretoobservethesewarningscouldresultin

severe injury or death.

Crimping Direction

First Compression

Crimping Direction

SIDE A

Crimping Direction

SIDE B

First Compression

SIDE A

First Compression

SIDE B

Installing Dies

1. Select the proper dies for the intended crimp.

2. Slide the die into the crimping head until it “snaps”

into place.

3. Properlypositiontheseconddie.RepeatStep2.

Preparing Cable

Followthelugmanufacturer’sinstructionsforappropri-

ate cable strip length.

Signal Duration When it occurs What it means

a few seconds of battery insertion self check - O.K.

ﬂashing

glowing for after crimp battery discharged

20 seconds

ﬂashing for after crimp time for inspection

20 seconds (2Hz) and preventive

maintenance

20 sec. glowing after crimp

battery discharged—

and ﬂashing time for inspection

intermittently and preventive

maintenance

Greenlee / A Textron Company 8 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Die Selection

CrimpsmadeoncoppercablewithGreenleeKC4-type

diesandthecopperconnectorslistedherearecULand

ULclassied.

CrimpsmadeoncopperoraluminumcablewithGreen-

leeKA4-typediesandthealuminumconnectorslisted

herearecULandULclassied.

Referto“ConnectorSelection”forbrandnamesand

modelnumbersofappropriatelugsaswellascrimping

instructions.

Connector Selection

Tool Range: Copper – 8 AWG to 300 kcmil copper wire; Dual-rated Aluminum – 8 AWG to 2/0 AWG copper or aluminum wire

When used with KC4-type dies, this tool is cUL and UL classiﬁed for use with the following connector brands:

Dies for Copper Connectors

Dies for Service Entrance Connectors

  * Usethenumberofcrimpslistedinthelastcolumninsteadofthenumberprovidedwiththeconnector:

 A— 8to1/0AWG:1crimp B— 8to2AWG:2crimps

  2/0AWGto300kcmil:2crimps  1to2/0AWG:3crimps

 ** 6AWGto300kcmil

*** 6AWGto2/0AWG

Dies for Aluminum Connectors

When used with KA4-type dies, this tool is cUL and UL classiﬁed for use with the following connector brands:

Catalog UPC Cable Color

Number Number Size Code

KA4-8 12222 8 AWG Blue

KA4-6 12223 6 AWG Gray

KA4-4 12225 4 AWG Green

KA4-2 12226 2 AWG Pink

KA4-1 12227 1 AWG Gold

KA4-1/0 12228 1/0 AWG Tan

KA4-2/0 12229 2/0 AWG Olive

Catalog UPC Cable Color

Number Number Size Code

KC4-8 02075 8 AWG Red

KC4-6 02076 6 AWG Blue

KC4-4 02077 4 AWG Gray

KC4-2 02078 2 AWG Brown

KC4-1 02079 1 AWG Green

KC4-1/0 02080 1/0 AWG Pink

KC4-2/0 02081 2/0 AWG Black

KC4-3/0 02082 3/0 AWG Orange

KC4-4/0 02083 4/0 AWG Purple

KC4-250 02084 250 kcmil Yellow

KC4-300 10988 300 kcmil White

Catalog UPC

Number Number

Usage

KD4-10 02021 5/8" Service Entrance

KD4-840 02022 840 Service Entrance

Connector Barrel Anderson Blackburn

FCI Burndy Ilsco Panduit T&B Penn- No. of

Type Type Union Crimps*

Dual-rated

Aluminum

Splice

— VACS ASP YS-A AS

60501-60536 PIK B

— VACL ATL

YA-A

ACL/ACN

LAA/LAB

60101-60138

BLUA B

YA-ATN

2ACL/2ACN

***

60230-60238

***

Dual-rated

Aluminum

Lugs

Connector Barrel Anderson Blackburn

FCI Burndy Ilsco Panduit T&B Penn- No. of

Type Type Union Crimps*

Copper Short VHSS** CSP YS-L CT SCSS/SCS 54504–54520 BCU

Splice

Long VHS** CU YS CTL SCL/SCH 54804–54820 BBCU

Short VHCS** CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54104–54120 BLU

Copper YA/YA-L-TC/YA-L-2TC LCD 54204–54218

Lugs Long VHCL** CTL-L/LCN YA-2N CRA-L/CRB-L LCB/LCC 54930BE–54920BE BBLU

CRA-2L/CRB-2L 54850BE–54878BE

Greenlee / A Textron Company 9 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Maintenance

Each Operating Day

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.

Skininjectionhazard:

Donotusehandstocheckfor

oilleaks.Highpressureoileasily

puncturesskincausingserious

injury,gangrene,ordeath.Ifinjured,

seekmedicalhelpimmediatelyto

remove oil.

Do not use solvents or ammable

cleaners to clean the tool body.

Solventscouldignite,causing

serious injury or property damage.

Afteruse:

1. Wipealltoolsurfacescleanwithadampclothand

mild detergent.

Troubleshooting

Before You Begin

1. Makesurethatthebatteryischarged.Recheck

thebatteryafterseveralminutestomakesurethe

battery is holding its charge.

Toolisinoperative. Dirt,contaminants,etc.,inramarea Cleantool.

of tool.

 Crimpingtoolbatterycontacts Reformcontacts.

damaged.

 Toolcomponentswornordamaged. Returntooltoanauthorized

Greenlee service center.

Diesstopduringoperation. Oillevelislow. Returntooltoanauthorized

Greenlee service center.

 Airinhydraulicsystem. Pulltriggerandholdretractbutton

simultaneously. Hold for approximately

10 seconds.

LEDglowsfor20seconds. Batterychargelow. Chargeorreplacebattery.

Tool loses oil. Damaged internal seal. Return tool to an authorized

Greenlee service center.

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.

Probable Cause

Problem

Probable Remedy

2. Fully retract the ram. Place the tool in the carrying

case.Storeinacool,dryplace.

3. Chargethebattery.

Monthly

1. Thoroughly clean all surfaces.

2. Oilthepinjoints.

Annually or After 10,000 Crimps

Return the tool to an authorized Greenlee service center

for inspection.

Greenlee / A Textron Company 10 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

101

100

102

141

146

144

143

147

142

148

145

141

140

Illustrations

Main

Greenlee / A Textron Company 11 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Illustrations (cont’d)

Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly

123

122

121

120

Motor Assembly

Greenlee / A Textron Company 12 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Parts List

Key Part No. Description Qty Key Part No. Description Qty

 7*  O-ring .................................................................1

 8*  Backupring,piston ............................................1

 9 50019082 Bushing ..............................................................1

 10 50019287 Lever,reliefvalve ................................................1

 11 50019295 Screw .................................................................1

 12 52026640 Switch .................................................................1

 13 50019414 Decal,GreenleeGATOR .....................................1

 14 50019422 Decal,GreenleeGATOR .....................................1

 15 50019430 Decal,warning ....................................................1

 16 50019660 Decal,specication ............................................1

 17 50019708 Decal,pinchhazard ............................................1

  50018922 Reliefvalveunit(includes30–39)

 30*  Seal ....................................................................1

 31 50019554 Valveseat ...........................................................1

 32 50019465 Needlevalve .......................................................1

 33 50019546 Plunger ...............................................................1

 34 50103776 Spring .................................................................1

 35 50070150 Lockwasher .......................................................2

 36*  O-ring .................................................................1

 37*  O-ring .................................................................1

 38 50019520 Pressurerelief .....................................................1

 39 50109146 Screw .................................................................1

  50018930 Pumphousingunit(includes50–56)

 50 52055861 Clamp,10pack ....................................................

 50*  Clamp .................................................................2

 51 50019023 Screw .................................................................1

 52 50109162 Threadedbushing ..............................................1

 53 50019562 Pumpblock ........................................................1

 54 50109308 Threadedbushing ..............................................1

 55 50109316 Screen ................................................................1

 56 50019449 Reservoir ............................................................1

  50018957 Motorassembly(includes70–79)

 70 50019651 Retainingring .....................................................1

 71 50019589 Pin ......................................................................1

 72 50019619 Motorcap ...........................................................1

 73 50019538 Dischousing .......................................................1

 74 50019627 Disc ....................................................................2

 75 50019791 Screw .................................................................2

 76 50019740 Gearlube,1.5g ..................................................1

 78 50109332 Motoradapter ....................................................1

 79 50018965 Motor,electric .....................................................1

  50018981 Headunit(includes90–102)

 90 50019210 Bolt,shoulder .....................................................1

 91 50019058 Disc ....................................................................1

 92 50019236 Spring .................................................................1

 93 50034324 Retainingring .....................................................4

 94 50019198 Pin ......................................................................2

 95 50019295 Screw .................................................................1

 96 50019678 Spring .................................................................2

 97 50019031 Movablehead .....................................................1

 98 50019694 Pin ......................................................................1

 99 50019775 Screw .................................................................1

100 50019201 Ram adapter .......................................................1

101 50019040 Latchhead .........................................................1

102 50019180 Fixedhead ..........................................................1

  50018990 Pistonpumpassembly(includes120–123)

120 50019317 Pistonpump .......................................................1

121 50019015 Spring .................................................................1

122 50019309 Pistonpumphousing .........................................1

123*  Pistonseal ..........................................................1

  50109430 Housingunit,green(includes140–148)

140 50042076 Screw .................................................................4

141 50019767 Screw .................................................................2

142 50043960 Compressionspring,DA5.5xL14.0 ..................1

143 50019341 Link,trigger ........................................................1

144  Lever,batteryrelease .........................................1

145 Housing half .......................................................1

146  Housinghalf .......................................................1

147  Button,reliefvalve ..............................................1

148  Cover,trigger ......................................................1

 * 50047957 Sealkit(includesitemsmarkedwithanasterisk)

  50020196 Casewithinserts

  50107607 Decal,crimpingchart

  52026638 9.6Vbattery

  50021788 12Vcharger110VAC

  50021800 12Vcharger220VAC

  52023076 12Vcharger12VDC

USA 800-435-0786 Fax: 800-451-2632

815-397-7070 Fax: 815-397-1865

Canada 800-435-0786 Fax: 800-524-2853

International +1-815-397-7070 Fax: +1-815-397-9247

4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070

An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.

www.greenlee.com

Greenlee Gator EK410L Battery Powered Crimper User manual

Brand: Greenlee

Model: Gator EK410L Battery Powered Crimper

Category: Power tools

Type: User manual

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Greenlee Gator EK410L Battery Powered Crimper User manual

Greenlee Gator EK410L Battery Powered Crimper User manual

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