Greenlee GATOR EK410 Bedienungsanleitung

INSTRUCTION MANUAL

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

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

101

100

102

141

10 11

146

144

143

147

142

148

145

141

140

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