Textron Greenlee GATOR EK410L Manuel utilisateur

OPERATION MANUAL

GATOR®EK410L

Battery-powered

Crimping Tool

Serial Number

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

EK410L Battery-powered Crimping Tool

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

Description

The EK410L Battery-powered Crimping Tool is a

hand-held, self-contained crimping tool intended to

crimp copper and aluminum cable with KC4-type dies.

This tool is protected by U.S. Patent No. 6,276,186,

6,401,515, 6,718,870, 7,086,979, and 7,254,982.

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 all personnel with

the safe operation and maintenance procedures for the

following Greenlee tool:

EK410L Battery-powered Crimping Tool

Keep this manual available to all personnel.

Replacement manuals are available upon request

at no charge at www.greenlee.com.

Do not discard this product or throw away!

For recycling information, go to www.greenlee.com.

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.

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 and Connector Selection ......................................... 8

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

Troubleshooting............................................................ 10

EK410L Battery-powered Crimping Tool

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

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, dened below,

indicates the severity of the hazard. The message

after the signal word provides information for pre-

venting or avoiding the hazard.

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.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

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.

Electric shock hazard:

This tool is not insulated. When

using this unit on or 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.

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, gan-

grene, or death.

Do not use solvents or ammable

liquids to clean the tool body.

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 sounds and the ram automatically

retracts to indicate a completed crimp. If you do

not hear the sound of the relieve valve or the ram

does not automatically retract, the crimp is not

complete.

Failure to observe these warnings could result in

severe injury or death.

EK410L Battery-powered Crimping Tool

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

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 improp-

erly assembled tool can break and strike nearby

personnel.

Failure to observe this warning could result in severe

injury or death.

• Do not use this tool for continuous use. After 30 to

40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is

designed for hand-held operation.

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

ments; however, air-drying is recommended before

use if the tool becomes soaked. Damage may

result when the tool is operated prior to thorough

drying when electrical components are 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 122 °F

(50°C) or less than –4 °F (–20 °C). 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.

Note: Keep all decals clean and legible, and replace

when necessary.

IMPORTANT SAFETY INFORMATION

EK410L Battery-powered Crimping Tool

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

Identiﬁcation

Speciﬁcations

Crimping Tool

Length..................................................................................................... 13.25" (336.5 mm)

Width .......................................................................................................... 2.87" (72.9 mm)

Depth............................................................................................................. 4.5" (114 mm)

Weight............................................................................................................. 4.0 lb (1.8 kg)

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

Hydraulic Oil ......................................................... 52057878 biodegradable hydraulic uid

Recommended Operating Temperature Range...................5 °F to 122 °F (–15 °C to 50°C)

Battery Charger........................................................................ Read the instructions supplied

with the battery charger

1. Latch

2. Crimping Dies

3. Crimping Head

4. Retract Button

5. LED Indicator (red)

6. Battery Lock

7. Battery Cartridge

8. LED Work Light (white)

9. Trigger

52047087 120 VAC corded adapter

52047088 230 VAC corded adapter

52049190 18 V, 1.5 Ah lithium-ion battery

52049189 18 V, 3.0 Ah lithium-ion battery

52054992 Li (18 V) to NiCd, NiMH (12 V) charger adapter

52049201 120 VAC, 18 V charger

52049202 230 VAC, 18 V charger

52049204 12 VDC, 18 V charger

EK410L Battery-powered Crimping Tool

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

Operation

Inspect tool and dies before use. Replace any

worn or damaged parts. A damaged or improp-

erly assembled tool can break and strike nearby

personnel.

Failure to observe this warning could result in severe

injury or death.

Electric shock hazard:

This tool is not insulated. When

using this unit on or 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.

• Do not use this tool for continuous use. After 30 to

40 cycles, allow the tool to cool for 15 minutes.

• Do not secure this tool in a vise. This tool is

designed for hand-held operation.

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

ments; however, air-drying is recommended before

use if the tool becomes soaked. Damage may

result when the tool is operated prior to thorough

drying when electrical components are soaked.

• Use this tool for the manufacturer’s intended

purpose only.

Failure to observe these precautions may result in

injury or property damage.

Charging the Battery

Read the instructions supplied with the battery charger.

LED Work Light (white)

This LED automatically turns on when the trigger is

pulled. It remains on for 10 seconds after the trigger is

released.

LED Indicator (red)

This tool is equipped with a special circuit board incor-

porating several important features to inform the user

about the current status of the unit. The LED signals in

the following cases:

What happens Signal What it means

Flashing light for 2seconds Battery is inserted in tool

Constant light for 20seconds

at end of cycle

Battery charge is below

17V at beginning of cycle

Tool will not start, and

constant light for 20seconds

when trigger is released

Battery charge is below

16V at beginning of cycle

Tool will stop, and constant

light for 20seconds after

trigger is released

Battery voltage drops

below 13V during cycle

Tool will stop, and ﬂashing

light for 20seconds when

trigger is released

Motor current exceeds

20A during cycle

Circuit has become too hot

Pressure Sensor

This tool is equipped with a pressure sensor that alerts

the user of an incomplete crimp.

• If the tool is manually retracted before completion of a

crimp, the red LED and an audible beep will be active

for 2 seconds.

• If the tool is unable to reach the required crimp force,

the red LED, work light, and an audible beep will pulse

until after the trigger is released.

EK410L Battery-powered Crimping Tool

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

Operation (cont’d)

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.

Crimping Direction

First Compression

Crimping Direction

SIDE A

Crimping Direction

SIDE B

First Compression

SIDE A

First Compression

SIDE B

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 ram retracts 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 sounds and the ram automatically

retracts to indicate a completed crimp. If you do

not hear the sound of the relieve valve or the ram

does not automatically retract, the crimp is not

complete.

Failure to observe these warnings could result in

severe injury or death.

EK410L Battery-powered Crimping Tool

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

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 Greenlee 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 alumimum wire

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

Connector

Type

Barrel

Type Anderson Blackburn®Burndy ILSCO Panduit T&B Penn-

Union

No. of

Crimps*

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

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

Copper Lugs

Short VHCS** CTL-2/CTL YA-2LN/YA-L/YA-2L

YA/YA-L-TC/YA-L-2TC

CSW

CRA/CRB

LCAS/LCA

LCD

54104–54120

54204–54218 BLU

Long VHCL** CTL-L/LCN YA-2N

CLN/CLW

CRA-L/CRB-L

CRA-2L/CRB-2L

LCB/LCC 54930BE–54920BE

54850BE–54878BE BBLU

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

Connector

Type

Barrel

Type Anderson Blackburn®Burndy ILSCO Panduit T&B Penn-

Union

No. of

Crimps*

Dual-rated

Aluminum

Splice

— VACS ASP YS-A AS

ASN

*** 60501–60536 PIK B

Dual-rated

Aluminum

Lugs

— VACL ATL YA-A

YA-ATN

ACL/ACN

2ACL/2ACN

ALNS/ALNN/ALND

LAA/LAB

***

60101–60138

60230–60238 BLUA B

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

B — 8 to 2 AWG: 2 crimps

1 to 2/0 AWG: 3 crimps

A — 8 to 1/0 AWG: 1 crimp

2/0 AWG to 300 kcmil: 2 crimps

** 6 AWG to 300 kcmil

***6 AWG to 2/0 AWG

Dies for Copper Connectors

Catalog No. UPC No. Cable Size Color 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

Dies for Aluminum Connectors

Catalog No. UPC No. Cable Size Color 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 Ta n

KA4-2/0 12229 2/0 AWG Olive

Dies for Service Entrance Connectors

Catalog No. UPC No. Usage

KD4-10 02021 5/8" Service Entrance

KD4-840 02022 840 Service Entrance

EK410L Battery-powered Crimping Tool

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

Maintenance

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.

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, gan-

grene, or death.

Do not use solvents or ammable

liquids to clean the tool body.

Solvents or ammable liquids could

ignite and cause serious injury or

property damage.

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.

Relief valve adjustments must be done by an

authorized service center.

Daily

Before use:

1. Inspect the tool for wear or damage, such as cracks,

gouges, or chips.

2. Inspect the tool for damage or leaks.

3. Inspect the rotation of the head assembly. Fully

retract the ram. The head should rotate no more

than 360°. If damage is detected, send the tool to a

Greenlee Authorized Service Center for inspection.

After use:

1. Use a damp cloth and mild detergent to clean the

housing. Allow the housing to dry.

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

case and store in a cool, dry place.

3. If necessary, recharge the batteries. Refer to the

instructions supplied with the battery charger.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

Annually or After 10,000 Crimps

1. Replace the hydraulic oil.

2. Send the tool to a Greenlee Authorized Service

Center for inspection.

Checking the Oil Level

1. Remove the screws holding the housing cover

together.

2. Point the crimping head downward and remove the

oil reservoir plug. Fill reservoir if necessary.

3. Replace the oil plug and housing cover.

EK410L Battery-powered Crimping Tool

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

Problem Possible Cause Probable Remedy

Tool is inoperative. Dirt, contaminants, etc., in ram area

oftool.

Clean tool.

Tool battery contacts damaged. Reform contacts.

Tool components worn or

damaged.

Return tool to a Greenlee Authorized Service

Center.

Motor is inoperative. Low or uncharged battery. Try known charged battery. Inoperative battery

may be discharged or may have reached life

expectancy.

Broken switch components. Return tool to a Greenlee Authorized Service

Center.

Motor runs but tool will not

complete a cycle.

Oil level low. Return tool to a Greenlee Authorized Service

Center.

Air in hydraulic system. Pull trigger and hold retract button simultane-

ously. Run for approximately 10 seconds, and

then attempt to crimp. If unsuccessful, return

tool to a Greenlee Authorized Service Center.

Cold oil. Pull trigger and hold retract button simultane-

ously to warm oil. Store tool in warm area.

Dies stop during operation. Oil level low. Return tool to a Greenlee Authorized Service

Center.

Air in hydraulic system. Pull trigger and hold retract button simultane-

ously. 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 a Greenlee Authorized Service

Center.

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.

2. Use a nonﬂammable contact cleaner or pencil

eraser to clean the electrical contacts on the battery

and tool.

3. Reinstall the battery and check the tool again.

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