Textron GREENLINE GATOR EK6IDL User manual

OPERATION MANUAL
GATOR®EK6IDL
Battery-powered
Dieless Crimping Tool
52066203 REV 2 © 2016 Greenlee Textron Inc. 7/16
Serial Number
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

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The EK6IDL Battery-powered, High-speed Dieless
Crimping Tool is a hand-held, self-contained crimping
tool intended to crimp copper cable.
This tool is protected by U.S. Patent No. 6,276,186,
6,401,515, 6,718,870, 7,086,979, 7,216,523, 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:
EK6IDL Battery-powered Dieless 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
cUL and UL Classied Crimps ................................... 8–9
Connector Table...................................................... 8–9
Maintenance................................................................. 10
Troubleshooting............................................................ 11

EK6IDL Battery-powered Dieless 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 connector and cable combinations.
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.

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
Pinch points:
• Remove battery before changing
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 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 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

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Specifications
Crimping Tool
Length........................................................................................................ 15.75" (400 mm)
Width .......................................................................................................... 2.87" (72.9 mm)
Depth........................................................................................................... 4.50" (114 mm)
Weight................................................................................................................ 6.6 lb (3 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. Indenter
2. Head
3. Latch
4. Retract Button
5. LED Indicator (red)
6. Battery Lock
7. Battery Cartridge
8. LED Work Light (white)
9. Trigger
5
4
7
9
2
1
6
8
3
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

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Operation
Inspect tool 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.
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
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.

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Preparation
For a cUL or UL classied crimp, refer to the
“Connector Table” in this instruction manual.
1. Select a proper size and type of connector to
correspond with the wire or cable.
2. Strip the cable to an appropriate length. Follow the
connector manufacturer’s instructions.
Note: Apply an oxide inhibitor, if required.
Refer to the connector manufacturer’s instructions.
Crimping
1. Insert the cable fully into the connector.
2. Place the connector into the V of the crimping head,
as shown below.
Connector
3. If open, close the crimping head. Make sure the
head and latch are fully engaged.
4. For a cUL or UL classied crimp, complete the
number of crimps specied in the “Connector Table”
in this manual.
5. For a single crimp, position the connector so the
crimp will be located at the center of the barrel.
6. Depress the trigger to advance the indenter. Hold
the trigger down until the indenter automatically
begins to retract.
Note: If the crimping tool does not automatically
retract, the crimp is incomplete.
It is normal for the battery load display to light at
both the beginning and near the end of the crimping
cycle.
7. Release the trigger until the indenter retracts
completely.
8. To stop the ram from returning fully, activate the
trigger for a brief moment. This activation will close
the retraction valve and stop the retraction motion.
9. Lift the latch to open the crimping head and remove
the connector.
Note: If it is necessary to retract the indenter before
a crimp cycle is complete, push the retract button.
Pushing the retract button will result in complete
retraction of the indenter.
An incomplete crimp can cause a re.
• Use proper connector and cable combinations.
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.
Operation (cont’d)

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
cUL and UL Classified Crimps
Crimps made with the Greenlee EK6IDL Dieless Crimping
Tool are cUL and UL classied on standard concentric,
compressed, or compact stranded copper cable with the
connectors listed here.
Refer to the “Connector Table” for the brand names
and model numbers of appropriate connectors and the
number of crimps required.
Connector Table
COPPER
Connector Type ** Anderson Blackburn® Burndy ILSCO Panduit T & B
Penn-
Union ** Tyco (AMP)
Copper Splices VHSS
VHS
CSP
CU
YS-L
YS
CT
CTL
SCSS
SCS
SCL, SCH
54506 to 54528
54806 to 54828
BCU
BBCU
1-1443402-5 to
1-1443403-5
Copper Lugs VHCS
VHCL
CTL
CTL-L
LCN
YA, YA-L, YA-2L
YA-2LN, YA-2N
YA-L-TC, YA-L-2TC
YA-2TC, YAZ
YAZ-2N, YAZ-2TC
CLN, CLW, CSW
CRA, CRB, CRC
CRA-L, CRB-L
CRA-2L, CRB-2L
CRC-2L
LCAS
LCA, LCB
LCD, LCC
LCAN
54106 to 54128
54206 to 54228
54906BE to 54928BE
54854BE to 54882BE
BLU
BBLU
1-1099899-7
to 1-1099939-3
*
Number of Crimps
Cable Size:
8 AWG to 600 kcmil
1 1 1 1 1 1 1 1
ALUMINUM
Connector Type Anderson Burndy ILSCO *** Panduit Penn-Union
Dual-Rated
Aluminum Splices VACS YS-A AS, ASN SA PIK BCUA
Dual-Rated
Aluminum Lugs VACL YA-A YA-A-TN
ACL, ACN
2ACL, 2ACN
ALNS, ALNN
ALND
LAA
LAB BLUA
*
Number of Crimps
Cable Size:
8 AWG to 350 kcmil
11111
* When crimping with the EK6IDL crimping
tool, use the number of crimps listed in this
table instead of the number provided with the
connector.
** 6 AWG to 600 kcmil
*** 6 AWG to 350 kcmil
95R7

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Connector Table (cont’d)
FLEX
COPPER
Class Diesel
Locomotive Burndy Ilsco Panduit T & B Penn-Union
G H I K M
8 AWG X X X X BCU, BBCU, BLU, BBLU-8
8 AWG X X X X 8 AWG 5104BS
8 AWG XXXXX 8 AWG YA8C CS8, CL8 LCAX8 54104, 54130, 54131, 54132, 256-30695-424
6 AWG XXXX 6 AWG CS6 ,CL6, CL4, CS4
6 AWG X BCU, BBCU, BLU, BBLU-6
6 AWG X X X BCU, BBCU, BLU, BBLU-5
6 AWG XXXXX 6 AWG YA5C LCAX6 256-30695-1361, 54134, 54105, 54135, 54136,
256-30695-282, 256-30695-422
4 AWG XXXXX 4 AWG YAC3 CS3, CL3, CS2, CL2 LCAX4 54139BS, 256-30695-1362, 54138, 54106, 54139,
54140, 256-30695-233, 256-30695-264 BCU, BBCU, BLU, BBLU-3
4 AWG X X X X X 5, 4, 3 AWG LCAX4
2 AWG XXXXX 2 AWG YA1C CS1, CL1 LCAX2 54147BS, 54107, 54142-TB, 54143-TB, 54145-TBN BCU, BBCU, BLU, BBLU-1
1 AWG X X X X 1 AWG BCU, BBCU, BLU, BBLU-1/0
1 AWG XXXXX 1 AWG YA25 CS1/0, CL1/0 LCAX1 54153BS, 54108, 54147, 54148, 54150
1/0 AWG XXXXX 1/0 AWG YA26 CS2/0, CL2/0 LCAX1/0 54110BS, 54152-TB, 54153-TB, 54109,
54155-TB, 256-30695-1383 BCU, BBCU, BLU, BBLU-2/0
2/0 AWG XXXX 2/0 AWG BCU, BBCU, BLU, BBLU-3/0
2/0 AWG X BCU, BBCU, BLU, BBLU-4/0
2/0 AWG XXXXX 2/0 AWG YA27 CS3/0, CL3/0 LCAX2/0 54165BS, 54157, 54158, 54110, 256-30695-131
3/0 AWG XXX 3/0 AWG BCU, BBCU, BLU, BBLU-4/0
3/0 AWG X BCU, BBCU, BLU, BBLU-025
3/0 AWG XXXXX 3/0 AWG YA28 CS4/0, CL4/0 LCAX3/0 54170BS, 54162-TB, 54163-TB, 54111, 54165-TB
4/0 AWG X X 4/0 AWG YA29 58165BS
4/0 AWG XXX 4/0 AWG YA30
4/0 AWG X X X 5411440BS
4/0 AWG XXXXX 4/0 AWG CS250, CL250 LCAX4/0 54167, 54168, 54112, 54170, 256-30695-1174 BCU, BBCU, BLU, BBLU-030
250 kcmil X X X X 262 kcmil 54114BS
250 kcmil X X 262 kcmil BCU, BBCU, BLU, BBLU-035
250 kcmil X BCU, BBCU, BLU, BBLU-040
250 kcmil X X YA30 CS300, CL300 5411440BS
250 kcmil X X X 262 kcmil YA31 54115260BS
250 kcmil X X X X X 262 kcmil CS350, CL350 LCAX250
300 kcmil X BCU, BBCU, BLU, BBLU-045
300 kcmil X X 313 kcmil BCU, BBCU, BLU, BBLU-040
300 kcmil X X X X X 313 kcmil YA32 CS400, CL400 LCAX300 54185BS
350 kcmil X X BCU, BBCU, BLU, BBLU-045
350 kcmil X X 373 kcmil BCU, BBCU, BLU, BBLU-050
350 kcmil X X 373 kcmil YA34 58177BS
350 kcmil X X X X X 373 kcmil CS500, CL500 LCAX350
400 kcmil X 444 kcmil BCU, BBCU, BLU, BBLU-060
400 kcmil X X BCU, BBCU, BLU, BBLU-050
400 kcmil X X X 444 kcmil YA34 58177BS
400 kcmil X X X X X 444 kcmil CS600, CL600
450 kcmil X 535 kcmil BCU, BBCU, BLU, BBLU-065
450 kcmil X X BCU, BBCU, BLU, BBLU-060
450 kcmil X X X 444 kcmil YA36 58180BS
500 kcmil X 535 kcmil YA38
500 kcmil X X X BCU, BBCU, BLU, BBLU-065
500 kcmil X X X X X 535 kcmil CS650, CL650,
CS700, CL700 54122BS

EK6IDL Battery-powered Dieless Crimping Tool
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
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
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.
Warranty Claims
Send tool to Greenlee CTSC Service Center.