Greenlee GATOR EK410 User manual

INSTRUCTION MANUAL
99947994 REV 11 © 2006 Greenlee Textron Inc. 12/06
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR®EK410
Battery-powered
Crimping Tool
Serialnummer

Greenlee / A Textron Company 24455 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.

Greenlee / A Textron Company 34455 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 44455 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:
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 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 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK410 Battery-powered Crimping Tool
4
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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/s2
Hydraulic Oil...................................................................................Shell Tellus®T 15
Crimping Capacities
Maximum 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 64455 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.
Pinch points:
Keep hands away from the crimping
head when crimping.
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.

Greenlee / A Textron Company 74455 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 84455 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 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

Greenlee / A Textron Company 94455 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
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141
10 11
146
12
15
144
143
147
142
148
145
141
140
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
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
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* 50041924 O-ring .................................................................1
8* 50041940 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* 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
50018930 Pump housing unit (includes 50–56)
50* 50019724 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* 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
* 50027255 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: [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