Textron Greenlee Utility GATOR EK622PLU User manual

OPERATION MANUAL
GATOR®EK622PLU
Battery-powered
Crimping Tool
52066131 REV 1 © 2014 Greenlee Textron Inc. 3/14
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
Serial Number

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The EK622PLU Battery-powered, High-speed Crimping
Tool is a hand-held, self-contained crimping tool
intended to crimp copper and aluminum cable with
KC22-type, KA22-type, and W-type dies.
This tool is protected by U.S. Patent No. 6,206,663,
6,267,186, 6,401,515, and 6,718,870.
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 Utility tool:
EK622PLU 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 Textron Innovations 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

EK622PLU 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 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.

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
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.
• Carrying strap is for carrying only, not to be used
to hang or suspend tool.
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.
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

EK622PLU 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 ............................................................................................14.3" (363.6 mm)
Width................................................................................................2.87" (72.9 mm)
Height (with battery) .......................................................................10.9" (278.5 mm)
Weight ................................................................................................9.26 lb (4.2 kg)
Crimping Force.................................................................................... 6 tons (53 kN)
Hydraulic Oil...............................................52057878 biodegradable hydraulic uid
Recommended Operating Temperature Range............. 5 °F to 122 °F (–15 °C to 50 °C)
Crimping Capacities
Maximum Cable Size
Copper................................................................................................... 600 kcmil
Aluminum............................................................................................... 350 kcmil
Battery Charger .............................................................Read the instructions supplied
with the battery charger
1. W-type Die Detents
2. Die Release Buttons
3. Locking Flange
4. Trigger
5. Battery
6. LED Work Light (white)
7. LED Indictor (red)
8. Retract Button
9. Housing
10. Lanyard Ring
52047087 120 VAC corded adapter
52047088 230 VAC corded adapter
52049189 18 V, 3 Ah lithium-ion battery
52049201 120 VAC, 18 V charger
52049202 230 VAC, 18 V charger
52049204 12 VDC, 18 V charger
52054992 Li (18 V) to NiCd, NiMH (12 V) charger adapter
50122746 Carrying strap
1
2 3 4
5
6
7
8
9
10

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
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.
• Carrying strap is for carrying only, not to be used
to hang or suspend tool.
Failure to observe these warnings 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.

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Operation (cont’d)
Installing K22, KA22, and KC22-type Dies
1. Select the proper dies for the intended crimp.
2. Push the die release button.
3. Slide the die into the crimping head until it “snaps”
into place.
4. Properly position the second die. Repeat steps 2
and 3.
Installing W-type Dies
1. Push the die release button.
2. Slide the die adapter (Greenlee part number
50042920) into crimping head until it “snaps” into
place.
Note: The die adapters have the “D3” die profile. No
additional dies are needed if the connector to be
crimped requires a “D3” die.
3. Repeat for the other adapter.
4. Select the proper dies for the intended crimp.
5. Press the locking ange and open the crimping
head.
6. Push the W-type die detent and slide the W-type die
into place.
7. Properly position the second die. Repeat steps 5
and 6.
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 and the ram retracts.
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.
Notes: 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.
After completing the last crimp with W-type dies on an
aluminum connector, wipe off the excess oxide inhibitor.
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.

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Die Selection
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.
W-type or X-type dies can be used to crimp 8 AWG to 500 kcmil copper and 8 AWG to 4/0 AWG aluminum.
95R7
Dies for Dual-rated Aluminum Connectors
Catalog Number UPC Number Cable 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 kcmil
KA22-300 06755 300 kcmil
KA22-350 06756 350 kcmil
Dies for Copper Connectors
Catalog Number UPC Number Cable Size Color 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 kcmil Yellow
KC22-300 03089 300 kcmil White
KC22-350 03090 350 kcmil Red
KC22-400 03091 400 kcmil Blue
KC22-500 03092 500 kcmil Brown
KC22-600 03093 600 kcmil Green
Connector Selection
Tool 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:
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 B
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 A
Long VHCL CTL-L/LCN YA-2N
CLN/CLW
CRA-L/CRB-L
CRA-2L/CRB-2L
LCB/LCC 54930BE-54920BE
54850BE-54878BE BBLU B
When used with KA22-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 SA** 60501-60565 PIK
C
Dual-rated
Aluminum Lugs — VACL ATL YA-A
YA-ATN
ACL/ACN
2ACL/2ACN LAA/LAB** 60101-60166
60230-60267 BLUA
C — 8 to 2 AWG: 2 crimps
1 to 3/0 AWG: 3 crimps
4/0 AWG to 350 kcmil: 4 crimps
B — 8 to 1/0 AWG: 2 crimps
2/0 to 3/0 AWG: 3 crimps
4/0 AWG to 600 kcmil: 4 crimps
A — 8 to 1/0 AWG: 1 crimp
2/0 AWG to 600 kcmil: 2 crimps
** 6 AWG to 350 kcmil
* Use the number of crimps listed in the last column instead of the number provided with the connector:

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
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 Utility 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 Utility 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.
Note: For Warranty Service or Repair, contact Greenlee
customer service at 800-435-0786.

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Problem Possible Cause Probable Remedy
Tool is inoperative. Dirt, contaminants, etc., in ram area
oftool.
Clean tool.
Tool components worn or damaged. Return tool to a Greenlee Utility
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 Utility
Authorized Service Center.
Motor runs but tool will not
complete a cycle.
Oil level low. Return tool to a Greenlee Utility
Authorized Service Center.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Run for approximately
10 seconds, and then attempt to
crimp. If unsuccessful, return tool to
a Greenlee Utility Authorized Service
Center.
Cold oil. Pull trigger and hold retract button
simultaneously to warm oil. Store tool
in warm area.
Dies stop during operation. Oil level low. Return tool to a Greenlee Utility
Authorized 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 a Greenlee Utility
Authorized Service Center.
Note: For Warranty Service or Repair, contact Greenlee customer service at 800-435-0786.
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.

EK622PLU Battery-powered Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11

4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
USA Tel: [phone]
Fax: [phone]
Canada Tel: [phone]
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