GATOR Battery-powered Crimping Tool Crimping Tool ... lee tools and equipment. ... flying debris or hydraulic oil. Do not use solvents or flammable

INSTRUCTION MANUAL

GATOR® EK410Battery-powered

Crimping Tool

99947994 REV 12 © 2010 Greenlee Textron Inc. 9/10

Serialnummer

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

Greenlee / A Textron Company 2 4455BoeingDr.•Rockford,IL61109-2988USA•815-397-7070

EK410 Battery-powered Crimping Tool

Allspecificationsarenominalandmaychangeasdesignimprove-ments occur. Greenlee Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products.

GATORisaregisteredtrademarkofGreenleeTextronInc.

BlackburnisaregisteredtrademarkofThomas&Betts.

TellusisaregisteredtrademarkofShellOilCompany.

KEEP THIS MANUAL

Table of ContentsDescription ..................................................................... 2

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

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

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

Identification ................................................................... 5

Specifications ................................................................. 5

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

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

ConnectorSelection ....................................................... 8

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

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

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

PartsList ...................................................................... 12

DescriptionTheEK410Battery-poweredCrimpingToolisa hand-held,self-containedcrimpingtoolintendedto crimpcopperandaluminumcablewithKC4-typedies.

SafetySafety is essential in the use and maintenance of Green-leetoolsandequipment.Thismanualandanymarkingson the tool provide information for avoiding hazards and unsafepracticesrelatedtotheuseofthistool.Observeall of the safety information provided.

Purpose of this ManualThismanualisintendedtofamiliarizeallpersonnelwith the safe operation and maintenance procedures for the followingGreenleetool:

EK410Battery-poweredCrimpingTool

Keep this manual available to all personnel.

Replacement manuals are available upon request at no chargeatwww.greenlee.com.



IMPORTANT SAFETY INFORMATION

This symbol is used to call your attention to hazardsorunsafepracticeswhichcouldresultinaninjuryorpropertydamage.Thesignalword,definedbelow,indicatestheseverityofthehazard.Themessageafterthesignalwordprovidesinfor-mation for preventing or avoiding the hazard.

Hazardsorunsafepracticeswhich,ifnotavoided,MAYresultininjuryorpropertydamage.

Hazardswhich,ifnotavoided,COULDresultinsevere injury or death.

Immediatehazardswhich,ifnotavoided,WILLresult 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.

Failuretoobservethiswarningcould result in severe injury or death.

Skininjectionhazard:

Donotusehandstocheckforoilleaks.Highpressureoileasilypuncturesskincausingseriousinjury,gangrene,ordeath.Ifinjured,seekmedicalhelpimmediatelytoremove oil.

Weareyeprotectionwhenoperatingor servicing this tool.

Failuretoweareyeprotectioncouldresult in serious eye injury from flying debris or hydraulic oil.

Do not use solvents or flammable liquids to clean the crimping tool. Solvents or flammable liquids could ignite and cause serious injury or property damage.

Anincompletecrimpcancauseafire.

•Useproperdie,connector,andcablecombina-tions. Improper combinations can result in an incomplete crimp.

•Thereliefvalvewillsoundtoindicateacompleted crimp. If you do not hear the sound of thereliefvalve,thecrimpisnotcomplete.

Failuretoobservethesewarningscouldresultinsevere injury or death.

Electricshockhazard:

Thistoolisnotinsulated.Whenusing this unit near energized electricallines,useproperpersonalprotective equipment.

Failuretoobservethiswarningcouldresult in severe injury or death.



IMPORTANT SAFETY INFORMATION

Note: Keep all decals clean and legible, and replace when necessary.

Pinchpoints:

•Removebatterybeforechangingdies,adapters,orjaws.

•Keephandsawayfromthecrimp-ingtoolheadwhencrimping.

Failuretoobservethesewarningscould result in severe injury or death.

Donotdisposeofbatteriesinafire.Theywillventfumes and may explode.

Failuretoobservethiswarningcouldresultinsevereinjury from harmful fumes or burns from flying debris.

Inspect tool and dies before use. Replace any wornordamagedparts.Adamagedorimproperlyassembledtoolcanbreakandstrikenearbyperson-nel.

Failuretoobservethiswarningcouldresultinsevereinjury or death.

•Donotoperatethetoolwithoutdies.Damagetothe ram or crimping head can result.

•Donotoperatewiththecrimpingheadopen.Damage to the ram or seals can result.

•Thistoolisnotdesignedforcontinuoususe.After100crimpingcycles,allowthecrimpingtool to cool for 15 minutes.

•Donotplacethetoolinavise.Thecrimpingtoolisdesignedforhand-heldoperation.

•Thistoolmaybeusedindamporwetenviron-ments;however,werecommendair-dryingthetoolbeforeuseifitbecomessoaked.

•Usethistoolforthemanufacturer’sintendedpurpose only.

Failure to observe these precautions may result in injury or property damage.

Donotallowanythingtocontactthebatteryterminals.

•Donotimmersethebatteriesinliquid.Liquidmay create a short circuit and damage the battery.Ifbatteriesareimmersed,contactyourservice center for proper handling.

•Donotplacethebatteryintoapocket,toolpouch,ortoolboxwithconductiveobjects.Conductiveobjectsmaycreateashortcircuitand damage the battery.

•Donotplaceabatteryonmoistgroundorgrass. Moisture may create a short circuit and damage the battery.


•Donotstorethebatteryatmorethan60°C (140°F).Damagetothebatterycanresult.

•Donotuseanothermanufacturer’scharger.Othermanufacturers’chargersmayoverchargeand damage the battery.

•Donotattempttoopenthebattery.Itcontainsnouser-serviceableparts.


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.



4

3

2

1

5

6

8

7

IdentificationIdentification

Specifications

1. CrimpingDies

2. CrimpingHead

3. RetractButton

4. BatteryLock

5. BatteryCartridge

6. Trigger

7. Latch

8. LEDDisplay

CrimpingTool

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

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

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

Mass/Weight(withbattery)...................................................................1.6kg(3.5lb)

SoundLevel .............................................................................. 75dB(A)at1meter

Vibration .................................................................................................... < 2.5 m/s2

HydraulicOil ...................................................................................Shell Tellus® T 15

CrimpingCapacities

CrimpingForce ................................................................................... 35kN(4tons)

AverageCrimpingTime .............................................................................4 seconds

AverageCrimpsperCharge ...........................................................approximately85

Battery

ChargingVoltage ............................................................................................... 9.6V

ChargingTime .................................................................................................45 min



Operation

•Donotoperatethetoolwithoutdies.Damagetothe ram or crimping head can result.

•Donotoperatewiththecrimpingheadopen.Damage to the ram or seals can result.

•Thistoolisnotdesignedforcontinuoususe.After100crimpingcycles,allowthecrimpingtool to cool for 15 minutes.

•Donotplacethetoolinavise.Thecrimpingtoolisdesignedforhand-heldoperation.

•Thistoolmaybeusedindamporwetenviron-ments;however,werecommendair-dryingthetoolbeforeuseifitbecomessoaked.

•Usethistoolforthemanufacturer’sintendedpurpose only.


Electricshockhazard:

Thistoolisnotinsulated.Whenusing this unit near energized electricallines,useproperpersonalprotective equipment.

Failuretoobservethiswarningcouldresult in severe injury or death.

Weareyeprotectionwhenoperatingor servicing this tool.

Failuretoweareyeprotectioncouldresult in serious eye injury from flying debris or hydraulic oil.

Pinchpoints:

•Removebatterybeforechangingdies,adapters,orjaws.

•Keephandsawayfromthecrimp-ingtoolheadwhencrimping.

Failuretoobservethesewarningscould result in severe injury or death.



Operation(cont’d)

Charging the Battery

Readtheinstructionssuppliedwiththebatterycharger.

LED Display

Thistoolisequippedwithaspecialcircuitboardincor-porating several important features to inform the user aboutthecurrectstatusoftheunit.TheLEDsignalsinthefollowingcases:

Crimping Cable

1. Pressthelockingflangeandopenthecrimpinghead.

2. Insert the properly assembled connector into the crimping head.

3. Closethecrimpinghead.

4. Pullthetriggertomakethecrimp.

5. Holdthetriggerdownuntilthecrimpingtoolachievespressurerelief,whichisaccompaniedbyan audible “pop”.

6. Thecrimpingtoolreturnsautomatically.

7. Position the crimping tool for next crimp. Repeat Steps4through6forthenumberofcrimpsasdescribed in this manual.

8. Openthecrimpingheadandremovetheconnector.

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.

Anincompletecrimpcancauseafire.

•Useproperdie,connector,andcablecombina-tions. Improper combinations can result in an incomplete crimp.

•Thereliefvalvewillsoundtoindicateacompleted crimp. If you do not hear the sound of thereliefvalve,thecrimpisnotcomplete.

Failuretoobservethesewarningscouldresultinsevere injury or death.Crimping Direction

First Compression

Crimping DirectionSIDE A

Crimping DirectionSIDE B

First CompressionSIDE A

First CompressionSIDE 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. Properlypositiontheseconddie.RepeatStep2.

Preparing Cable

Followthelugmanufacturer’sinstructionsforappropri-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



Die SelectionCrimpsmadeoncoppercablewithGreenleeKC4-typediesandthecopperconnectorslistedherearecULandULclassified.

CrimpsmadeoncopperoraluminumcablewithGreen-leeKA4-typediesandthealuminumconnectorslistedherearecULandULclassified.

Referto“ConnectorSelection”forbrandnamesandmodelnumbersofappropriatelugsaswellascrimpinginstructions.

Connector SelectionTool 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

* Usethenumberofcrimpslistedinthelastcolumninsteadofthenumberprovidedwiththeconnector:

A— 8to1/0AWG:1crimp B— 8to2AWG:2crimps 2/0AWGto300kcmil:2crimps 1to2/0AWG:3crimps

** 6AWGto300kcmil

*** 6AWGto2/0AWG

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 SA 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

A 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 A Lugs Long VHCL** CTL-L/LCN YA-2N CRA-L/CRB-L LCB/LCC 54930BE–54920BE BBLU CRA-2L/CRB-2L 54850BE–54878BE



Maintenance

Each Operating Day

Beforeuse:

1. Inspectdiesforwearordamagesuchascracks,gouges,orchips.

2. Inspectthetoolfordamageorleaks.Ifdamageisdetected,returnthetooltoanauthorizedGreenleeservice center for inspection.

Skininjectionhazard:

Donotusehandstocheckforoilleaks.Highpressureoileasilypuncturesskincausingseriousinjury,gangrene,ordeath.Ifinjured,seekmedicalhelpimmediatelytoremove oil.

Do not use solvents or flammable cleaners to clean the tool body. Solventscouldignite,causingserious injury or property damage.

Afteruse:

1. Wipealltoolsurfacescleanwithadampclothandmild detergent.

Troubleshooting

Before You Begin

1. Makesurethatthebatteryischarged.Recheckthebatteryafterseveralminutestomakesurethebattery is holding its charge.

Toolisinoperative. Dirt,contaminants,etc.,inramarea Cleantool. of tool.

Crimpingtoolbatterycontacts Reformcontacts. damaged.

Toolcomponentswornordamaged. Returntooltoanauthorized Greenlee service center.

Diesstopduringoperation. Oillevelislow. Returntooltoanauthorized Greenlee service center.

Airinhydraulicsystem. Pulltriggerandholdretractbutton simultaneously. Hold for approximately 10 seconds.

LEDglowsfor20seconds. Batterychargelow. Chargeorreplacebattery.

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

2. Usea nonflammable contact cleaner or pencil eraser to clean the electrical contacts on the battery and crimping tool.

3. Reinstallthebatteryandcheckthetoolagain.

Probable CauseProblem Probable Remedy

2. Fully retract the ram. Place the tool in the carrying case.Storeinacool,dryplace.

3. Chargethebattery.

Monthly

1. Thoroughly clean all surfaces.

2. Oilthepinjoints.

Annually or After 10,000 Crimps

Return the tool to an authorized Greenlee service center for inspection.



78

990

91

92

17101

94

93

95

96

100

99

98

97

102

141

1011

146

12

15

144

143

147

142

148

145

141 140

140

Illustrations

Main



Illustrations (cont’d)

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

56

54

53

52

55 50

3031

32

3334

3536

3738

39

51

123122

121

120

50

70

71

72

73

74

76

78

75

79

Motor Assembly



Parts List Key Part No. Description Qty Key Part No. Description Qty

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

8* Backupring,piston ............................................1

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

10 50019287 Lever,reliefvalve ................................................1

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

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

13 50019414 Decal,GreenleeGATOR .....................................1

14 50019422 Decal,GreenleeGATOR .....................................1

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

16 50019660 Decal,specification ............................................1

17 50019708 Decal,pinchhazard ............................................1

50018922 Reliefvalveunit(includes30–39)

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

31 50019554 Valveseat ...........................................................1

32 50019465 Needlevalve .......................................................1

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

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

35 50070150 Lockwasher .......................................................2

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

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

38 50019520 Pressurerelief .....................................................1

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

50018930 Pumphousingunit(includes50–56)

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

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

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

52 50109162 Threadedbushing ..............................................1

53 50019562 Pumpblock ........................................................1

54 50109308 Threadedbushing ..............................................1

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

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

50018957 Motorassembly(includes70–79)

70 50019651 Retainingring .....................................................1

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

72 50019619 Motorcap ...........................................................1

73 50019538 Dischousing .......................................................1

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

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

76 50019740 Gearlube,1.5g ..................................................1

78 50109332 Motoradapter ....................................................1

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

50018981 Headunit(includes90–102)

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

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

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

93 50034324 Retainingring .....................................................4

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

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

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

97 50019031 Movablehead .....................................................1

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

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

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

101 50019040 Latchhead .........................................................1

102 50019180 Fixedhead ..........................................................1

50018990 Pistonpumpassembly(includes120–123)

120 50019317 Pistonpump .......................................................1

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

122 50019309 Pistonpumphousing .........................................1

123* Pistonseal ..........................................................1

50109430 Housingunit,green(includes140–148)

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

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

142 50043960 Compressionspring,DA5.5xL14.0 ..................1

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

144 Lever,batteryrelease .........................................1

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

146 Housinghalf .......................................................1

147 Button,reliefvalve ..............................................1

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

* 50047957 Sealkit(includesitemsmarkedwithanasterisk)

50020196 Casewithinserts

50107607 Decal,crimpingchart

52026638 9.6Vbattery

50021788 12Vcharger110VAC

50021800 12Vcharger220VAC

52023076 12Vcharger12VDC

USA 800-435-0786 Fax: 800-451-2632 815-397-7070 Fax: 815-397-1865Canada 800-435-0786 Fax: 800-524-2853International +1-815-397-7070 Fax: +1-815-397-9247

4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.

www.greenlee.com

Documents

GATOR Battery-powered Crimping Tool Crimping Tool ... lee tools and equipment. ... flying debris or hydraulic oil. Do not use solvents or flammable