Greenlee GATOR EK425 User manual

INSTRUCTION MANUAL
99950391 REV 12 © 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®EK425
Battery-powered
Crimping Tool
Serialnummer

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 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.
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 and Connector Selection ......................................... 8
Maintenance................................................................... 9
Troubleshooting.............................................................. 9
Illustrations ............................................................. 10–13
Parts List ...................................................................... 14
Description
The EK425 Battery-powered Crimping Tool is a
hand-held, self-contained crimping tool with removable
crimping jaws.
Safety
Safety is essential in the use and maintenance of Fair-
mont tools and equipment. This manual and any mark-
ings 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 Fairmont tool:
EK425 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
EK425 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.
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 com-
pleted 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.
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.

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
IMPORTANT SAFETY INFORMATION
• This tool is not designed for continuous use.
After 30 to 40 crimping cycles, allow the crimp-
ing 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.
Inspect tool and dies before use. Replace any worn or
damaged parts. A damaged or improperly assembled
tool can break and strike nearby personnel.
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.
Keep hands away from the crimping
head when crimping.
Failure to observe this warning could
result in severe injury or death.
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.
Note: Keep all decals clean and legible, and replace
when necessary.
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
EK425 Battery-powered Crimping Tool
2
5
4
3
6
7
1
IdenticationIdentication
Specifications
1. Lock Pin
2. Crimping Jaws
3. Jaw Covers
4. Retract Button
5. Battery Lock
6. Battery Cartridge
7. Trigger
Crimping Tool
Length ...............................................................................................................465 mm (18-1/4")
Width.....................................................................................................................60 mm (2-3/8")
Depth ....................................................................................................................98 mm (3-7/8")
Mass/Weight (with battery)...................................................................................... 2.5 kg (5.5 lb)
Sound Level ..................................................................................................75 dB (A) at 1 meter
Vibration ........................................................................................................................< 2.5 m/s2
Hydraulic Oil...................................................................................................... Shell Tellus®T 15
Recommended Operating Temperature Range ................... -15 °C (5 °F) through 50 °C (120 °F)
Crimping Capacities
Maximum Crimping Force.......................................................................................44 kN (5 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
EK425 Battery-powered Crimping Tool
Operation
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.
• This tool is not designed for continuous use.
After 30 to 40 crimping cycles, allow the crimp-
ing 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.
Keep hands away from the crimping
head when crimping.
Failure to observe this warning could
result in severe injury or death.

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
Operation (cont’d)
Charging the Battery
Read the instructions supplied with the battery charger.
Die Selection
Interchangeable dies may be used in the standard die
opening. Dies that may be used include:
• Greenlee KD6 series
• Burndy W and X series
• ILSCO ND series
• Huskie HT58 series
• Panduit CD-2001 series
• Other industry W-type dies
Installing Dies
1. Select the proper dies for the connector to be
crimped.
2. Install dies in jaws making certain that they are
properly secured by the spring-loaded, positive
lock, die buttons.
Preparing Cable
Follow the lug manufacturer’s instructions for appro-
priate cable strip length.
Crimping Procedure
1. Insert conductor into the connector and align the
tool and die on the connector. Start in the center for
splices and “H” frames; and on the end, nearest the
pad, for terminals.
2. Activate the tool by pulling the trigger. Continue to
hold the trigger until the ram retracts. This is the
signal that the crimp is complete.
3. Continue crimping the connector until the correct
number of crimps has been completed. Work from
the center to the outer edges for splices and “H”
frame connectors, alternating sides if possible, for
the best compression connections.
Crimping Direction
First Compression
Crimping Direction
SIDE A
Crimping Direction
SIDE B
First Compression
SIDE A
First Compression
SIDE B
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 com-
pleted 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.

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
CJ22 Jaw and KA22/KC22-type Die Selection
Note: This tool will provide a cUL and UL classified crimp ONLY when used with the CJ22 jaws and KA22- or KC22-type dies.
Crimps made on copper cable with Greenlee KC22-type dies and the copper connectors listed here are
cUL and UL classied.
Crimps made on copper or aluminum cable with Greenlee KA22-type dies and the dual-rated 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
CJ22 Crimping Jaw Range: Copper — 8 AWG to 600 kcmil†; Dual-rated Aluminum — 8 AWG to 350 kcmil
When used with KC22-type dies, this tool is cUL and UL classied for use with the following connector brands:
Dies for Copper Connectors Dies for Dual-rated Aluminum Connectors
When used with KA22-type dies, this tool is cUL and UL classied for use with the following connector brands:
* 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 3/0 AWG: 3 crimps
4/0 AWG to 350 kcmil: 4 crimps
A — 8 to 1/0 AWG: 1 crimp
2/0 AWG to 600 kcmil: 2 crimps
** 6 AWG to 350 kcmil
†500 kcmil maximum with Penn-Union connectors
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 54504–54518 BCU
Splice Long VHS CU YS CTL SCL/SCH 54804–54818 BBCU
Short VHCS CTL-2/CTL YA-2LN/YA-L/YA-2L CRA/CRB LCAS/LCA 54104–54118 BLU A
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–54918BE BBLU
CRA-2L/CRB-2L 54850BE–54876BE
Connector Barrel Anderson Blackburn®FCI Burndy Ilsco Panduit T&B Penn- No. of
Type Type Union Crimps*
Dual-rated
Aluminum — VACS ASP YS-A AS SA 60501–60565 PIK
Splice ** B
Dual-rated YA-A ACL/ACN LAA/LAB 60101–60166
Aluminum — VACL ATL BLUA
Lugs YA-ATN 2ACL/2ACN ** 60230–60267
95R7
Catalog UPC Cable Color
Number Number Size Code
KC22-8 03079 8 AWG Red
KC22-6 03080 6 AWG Blue
KC22-4 03081 4 AWG Gray
KC22-2 03082 2 AWG Brown
KC22-1 03083 1 AWG Green
KC22-1/0 03084 1/0 AWG Pink
KC22-2/0 03085 2/0 AWG Black
KC22-3/0 03086 3/0 AWG Orange
KC22-4/0 03087 4/0 AWG Purple
KC22-250 03088 250 AWG Yellow
KC22-300 03089 300 AWG White
KC22-350 03090 350 AWG Red
KC22-400 03091 400 AWG Blue
KC22-500 03092 500 kcmil Brown
KC22-600B 08094 600 kcmil Green
Catalog UPC Cable
Number Number Size
KA22-8 06744 8 AWG
KA22-6 06745 6 AWG
KA22-4 06746 4 AWG
KA22-2 06747 2 AWG
KA22-1 06749 1 AWG
KA22-1/0 06750 1/0 AWG
KA22-2/0 06751 2/0 AWG
KA22-3/0 06752 3/0 AWG
KA22-4/0 06753 4/0 AWG
KA22-250 06754 250 AWG
KA22-300 06755 300 AWG
KA22-350 06756 350 AWG

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 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 Fairmont
service center for inspection.
Skin injection hazard:
Do not use hands to check for oil
leaks. High pressure oil easily punc-
tures 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.
Troubleshooting
Before You Begin
1. Make sure that the battery is charged. Recheck the
battery after several minutes to make sure the bat-
tery 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
Fairmont service center.
Dies stop during operation. Oil level is low. Return tool to an authorized
Fairmont service center.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately
10 seconds.
Tool loses oil. Damaged internal seal. Return tool to an authorized
Fairmont 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.
 Problem ProbableCause 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 Fairmont service center
for inspection.
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.

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
Illustrations
Main
1
11
68
62
67
63
9
64
65
60
60
61
66
61
10
12
8
7 6
59
69

Greenlee / A Textron Company 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
Illustrations (cont’d)
Pump Housing Unit, Relief Valve Unit, and Piston Pump Assembly
56
54
53
55 50
30
31
32
33
34 35
36 37
38
39
51
23
22
21
20
50
52
70
71
72
73
74
76
77
75
78
Motor Assembly

Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
Illustrations (cont’d)
Ram Unit and Crimping Jaw Unit—D3
90
110
114 113
115
118
116
117
111
110
118
91
92
93
94
95
96
97
100
101
103
102
99
98

Greenlee / A Textron Company 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
Illustrations (cont’d)
Crimping Jaw Unit—Kearney
119
121
120
117
116
111
115 110C
(plastic coated)
116
117
116
120
113
114
115
glued in with
Loctite 270
(green)
119
118
113
114
110B
111
Crimping Jaw Unit—“O”

Greenlee / A Textron Company 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
EK425 Battery-powered Crimping Tool
Parts List
Key Part No. Description Qty Key Part No. Description Qty
1* 50120050 Bushing with seal.............................................................1
6 50019295 Screw ..............................................................................1
7 50019287 Lever, relief valve .............................................................1
8 50019325 Switch..............................................................................1
9 50037030 Decal, specification ..........................................................1
10 50040650 Decal, Fairmont GATOR ....................................................1
11 50019708 Decal, pinch hazard..........................................................1
12 50045105 Decal, Fairmont GATOR ....................................................1
50018990 Piston pump assembly (includes 20–23)
20 50019317 Piston pump ................................................................1
21 50019015 Spring .........................................................................1
22 50019309 Piston pump housing...................................................1
23* Piston seal...................................................................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* 50019066 O-ring..........................................................................1
38 50019520 Pressure relief .............................................................1
39 50109146 Screw..........................................................................1
50032399 Pump housing unit (includes 50–56)
50* 50019724 Clamp .........................................................................2
51 50019023 Screw..........................................................................1
52 50109162 Threaded bushing........................................................1
53 50032445 Pump block .................................................................1
54 50109308 Threaded bushing........................................................1
55 50109316 Screen.........................................................................1
56 50019449 Reservoir.....................................................................1
50047892 Housing unit, red (includes 59–69)
59 50041983 Ring ............................................................................1
60 50042076 Screw..........................................................................4
61 50019767 Screw..........................................................................2
62 50043960 Compression spring, DA5.5 x L14.0)............................1
63 50019341 Link, trigger.................................................................1
64 Lever, battery release ..................................................1
65 Housing half ................................................................1
66 Housing half ................................................................1
67 Button, relief valve.......................................................1
68 Cover, trigger...............................................................1
69 50048066 Stud ............................................................................1
50018957 Motor assembly (includes 70–78)
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
77 50109332 Motor adapter..............................................................1
78 50018965 Motor, electric .............................................................1
50032410 Ram unit (includes 90–103)
90 50032542 Sheath ........................................................................1
91 50032550 Bolt, shoulder ..............................................................1
92 50032569 Disc.............................................................................1
93 50032585 Compression spring.....................................................1
94 50032623 Washer........................................................................1
95* O-ring..........................................................................1
96 50019295 Screw..........................................................................1
97 50032631 Ram housing ...............................................................1
98 50032640 Compression spring.....................................................1
99 50032658 Locking pin .................................................................1
100 50032666 Compression spring.....................................................1
101 50032674 Pin ..............................................................................1
102 50032682 Roller ..........................................................................2
103 50032690 Ram ............................................................................1
50032429 Crimping jaw unit, D3(includes 110–118)
50034448 Crimping jaw unit, “O” (includes 110–114 & 118)
50048295 Crimping jaw unit, Kearney
(includes 110–117, 119-121)
110A Jaw, D3.......................................................................2
110B Jaw, “O”......................................................................2
110C Jaw, Kearney...............................................................2
111 52022544 Extension spring..........................................................1
113 50032275 Retaining ring..............................................................2
114 50032500 Pin pivot ......................................................................1
115 Bushing.......................................................................2
116 Compression spring.....................................................2
117 Lock adapter ...............................................................2
118A 52021086 Jaw covers, CJO/CJD3 (set of 2)..................................1
118B 52022386 Jaw covers, CJK (set of 2) ...........................................1
119 50067249 Bushing.......................................................................2
120 50105159 Ball, 3mm....................................................................2
121 50105116 Locking pin .................................................................1
* 50047957 Seal kit (includes items marked with an asterisk)
50103750 Die pin kit, “W”-style dies (includes 115–117)
50105108 Die pin kit, Kearney-style dies
(includes 116, 119–121)
52025047 Carrying pouch
50048074 Strap, carrying
50019759 9.6 V battery
52020086 12 V charger 110 VAC
50021800 12 V charger 220 VAC
52023076 12 V charger 12 VDC
Optional Accessory
52024683 CJ22 crimping jaw unit for cUL and UL classified
crimps—refer to page 8 for details
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