OPERATION MANUAL
Serialnummer
GATOR® EK210L
Battery-powered
Crimping Tool
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
52047664 REV 2 © 2011 Greenlee Textron Inc. 2/11
EK210L Battery-powered Crimping Tool
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
Important Safety Information ..................................... 3–4
Identication ................................................................... 5
Specications ................................................................. 5
Operation .................................................................... 6–7
Maintenance ................................................................... 8
Troubleshooting .............................................................. 9
Description
The EK210L Battery-powered Crimping Tool is a
hand-held, self-contained crimping tool intended to
crimp cable using Kwik Cycle® 9 die sets.
This tool is protected by U.S. Patent No. 6,276,186,
6,401,515, 6,718,870, 7,086,979, 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:
EK210L 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 specications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
GATOR and Kwik Cycle are registered trademarks of
Greenlee Textron Inc.
KEEP THIS MANUAL
EK210L Battery-powered Crimping Tool
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, dened 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.
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, gangrene, 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.
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.
EK210L Battery-powered Crimping Tool
IMPORTANT SAFETY INFORMATION
Pinch points:
• Remove battery before changing
dies, adapters, or jaws.
• Keep hands away from the crimping 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 improperly assembled tool can break and strike nearby
personnel.
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 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 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 environments; 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 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.
Identification
1. Crimping Dies
2. Crimping Head
3. Retract Button
4. LED Indicator (red)
5. Battery Lock
6. Battery Cartridge
7. LED Work Light (white)
8. Trigger
EK210L Battery-powered Crimping Tool
6
5
4
3
2
1
7
Specifications
Crimping Tool
Length (with battery) ............................................................................... 12.75" (323.8 mm)
Width .......................................................................................................... 2.87" (72.9 mm)
Depth ........................................................................................................ 4.50" (114.3 mm)
Weight .............................................................................................................3.3 lb (1.5 kg)
Crimping Force ............................................................................................1.5 tons (13 kN)
Hydraulic Oil ......................................................... 52057878 biodegradable hydraulic uid
Recommended Operating Temperature Range ...................5 °F to 122 °F (–15 °C to 50°C)
Battery Charger ........................................................................Read the instructions supplied
8
with the battery charger
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
Operation
EK210L Battery-powered Crimping Tool
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.
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 crimping 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 environments; 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 2seconds
Constant light for 20seconds
at end of cycle
Tool will not start, and
constant light for 20seconds
when trigger is released
Tool will stop, and constant
light for 20seconds after
trigger is released
Tool will stop, and flashing
light for 20seconds when
trigger is released
Battery is inserted in tool
Battery charge is below
17V at beginning of cycle
Battery charge is below
16V at beginning of cycle
Battery voltage drops
below 13V during cycle
Motor current exceeds
20A 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.
Operation (cont’d)
EK210L Battery-powered Crimping Tool
Installing Dies
1. Select the proper dies for the intended crimp.
2. Slide the die into the crimping head and secure with
screw.
3. Properly position the second die. Repeat Step 2.
Preparing Cable
Follow the lug manufacturer’s instructions for appropri-
ate cable strip length.
Crimping Direction
First Compression
Crimping Direction
SIDE B
First Compression
SIDE A
First Compression
SIDE B
Crimping Direction
SIDE A
Crimping Cable
1. Insert the properly assembled connector into the
crimping head.
2. Pull the trigger to make the crimp.
3. Hold the trigger down until the crimping tool
achieves pressure relief, which is accompanied by
an audible “pop”.
4. The crimping tool returns automatically.
5. Position the crimping tool for next crimp. Repeat
Steps 2 and 3 for the number of crimps as
described in this manual.
Note: 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.
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.
Maintenance
EK210L Battery-powered Crimping Tool
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, gangrene, or death.
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.
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 crimping tool head when crimping.
Failure to observe these warnings
could result in severe injury or death.
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.
Relief valve adjustments must be done by an
authorized service center.
Troubleshooting
EK210L Battery-powered Crimping Tool
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.
Problem Possible Cause Probable Remedy
Tool is inoperative. Dirt, contaminants, etc., in ram area
oftool.
Tool battery contacts damaged. Reform contacts.
Tool components worn or damaged. Return tool to a Greenlee Authorized
Motor is inoperative. Low or uncharged battery. Try known charged battery. Inoperative
Broken switch components. Return tool to a Greenlee Authorized
Motor runs but tool will not
complete a cycle.
Oil level low. Return tool to a Greenlee Authorized
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.
Clean tool.
Service Center.
battery may be discharged or may have
reached life expectancy.
Service Center.
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 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 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 Authorized
Service Center.
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