Greenlee GATOR EK210 User manual

INSTRUCTION MANUAL
GATOR®EK210
Battery-powered
Crimping Tool
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99947986 REV 13 © 2007 Greenlee Textron Inc. 11/07
Serialnummer

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The EK210 Battery-powered Crimping Tool is a
hand-held, self-contained crimping tool intended to
crimp cable using Kwik Cycle®9 die sets.
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:
EK210 Battery-powered Crimping Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge at www.greenlee.com.
All specications 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 and Kwik Cycle are registered trademarks of
Greenlee Textron Inc.
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
Maintenance................................................................... 8
Troubleshooting.............................................................. 8
Illustrations ............................................................... 9–10
Parts List ...................................................................... 11

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
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 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. 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
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.
•
•

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
Pinch points:
Keep hands away from the crimping
head when crimping.
Failure to observe this warning 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 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.
•
•
•
•
•
•
IMPORTANT SAFETY INFORMATION
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.
Note: Keep all decals clean and legible, and replace
when necessary.

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Specifications
Crimping Tool
Length ..................................................................................................356 mm (14")
Width................................................................................................. 60 mm (2-3/8")
Depth................................................................................................. 80 mm (3-1/8")
Mass/Weight (with battery)...................................................................1.3 kg (2.8 lb)
Sound Level .............................................................................. 75 dB (A) at 1 meter
Vibration .................................................................................................... < 2.5 m/s2
Hydraulic Oil...................................................................................Shell Tellus®T 15
Crimping Capacities
Maximum Crimping Force................................................................ 13 kN (1.5 tons)
Average Crimping Time.............................................................................2 seconds
Average Crimps per Charge.........................................................approximately 150
Battery
Charging Voltage............................................................................................... 9.6 V
Charging Time.................................................................................................45 min
1. Crimping Dies
2. Crimping Head
3. Retract Button
4. Battery Lock
5. Battery Cartridge
6. Trigger
7. LED Display
4
3
2
1
5
6
7

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Operation
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:
Keep hands away from the crimping
head when crimping.
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.
•
•
•
•
•
•

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
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:
Installing Dies
1. Select the proper dies for the intended crimp.
2. Slide the die into the crimping head and secure with
screw.
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
Crimping Cable
1. Insert the properly assembled connector into the
crimping head.
2. Pull the trigger to make the crimp.
3. Hold the trigger down until the crimping tool
achieves pressure relief, which is accompanied by
an audible “pop”.
4. The crimping tool returns automatically.
5. Position the crimping tool for next crimp. Repeat
Steps 2 and 3 for the number of crimps as
described in this manual.
Note: If it is necessary to retract the ram before a
crimping 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

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
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.
After use:
1. Wipe all tool surfaces clean with a damp cloth and
mild detergent.
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.
2. Fully retract the ram. Place the tool in the carrying
case. Store in a cool, dry place.
3. Charge the battery.
Monthly
Thoroughly clean all surfaces.
Annually or After 10,000 Crimps
Return the tool to an authorized Greenlee service center
for inspection.
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 crimping tool.
3. Reinstall the battery and check the tool again.
Problem Probable Cause Probable Remedy
Tool is inoperative. Dirt, contaminants, etc., in ram area
of tool.
Clean tool.
Crimping tool battery contacts
damaged.
Reform contacts.
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 approxi-
mately 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.

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Illustrations—Main
90
91
92
17
97
98
95
14
141
10 11
146
12
15
144
143
147
16
142
148
145
140
140
93
13
141
96 94
7

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Illustrations (cont’d)
56
54
53
52
55 50
30
31
32
33
34
35 36 37
38
39
51
123
122
121
120
50
70
71
72
73
74
76
78
75
79
Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly
Motor Assembly

EK210 Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Parts List
Key Part No. Description Qty
7* 50120050 Bushing with seal..................................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 50020285 Decal, specication...............................1
17 50019708 Decal, pinch hazard ..............................1
50018922 Relief valve unit (includes 30–39)
30* 50058622 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* 50063707 O-ring....................................................1
37* 50019066 O-ring....................................................1
38 50019520 Pressure relief .......................................1
39 50109146 Screw....................................................1
50018949 Pump housing unit (includes 7, 8, 50–56)
50* 50019724 Clamp ...................................................2
51 50019023 Screw....................................................1
52 50109162 Threaded bushing.................................1
53 50019570 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
90 50019228 Bolt, shoulder........................................1
91 50019155 Cap .......................................................1
92 50019163 Compression spring..............................1
93 50019120 Compression spring..............................1
94 50019112 Washer..................................................1
95 50109367 Crimping head ......................................1
96 50019716 Screw....................................................2
97 50109898 Die holder..............................................1
98 50019295 Screw....................................................1
50018990 Piston pump assembly (includes 120–123)
120 50019317 Piston pump..........................................1
121 50019015 Spring ...................................................1
122 50019309 Piston pump housing............................1
123* 50103695 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
* 50027247 Seal kit (includes items marked
with an asterisk)
50020196 Case with inserts
52026638 9.6 V battery
50021788 12 V charger 110 VAC
50021800 12 V charger 220 VAC
52023076 12 V charger 12 VDC
Key Part No. Description Qty

USA 800-435-0786 Fax: [phone]
815-397-7070 Fax: [phone]
Canada 800-435-0786 Fax: [phone]
International [phone] Fax: [phone]
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 Printed in USA