GREENLINE EK6IDL Operation Manual

OPERATION MANUAL

Serial Number

GATOR® EK6IDL

Battery-powered

Dieless Crimping Tool

Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

52066203 © 2014 Greenlee Textron Inc. 2/14

Register this product at www.greenlee.com

EK6IDL Battery-powered Dieless Crimping Tool

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

Connector Table .......................................................... 8

Maintenance ................................................................... 9

Troubleshooting ............................................................ 10

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 improve­ments 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.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

KEEP THIS MANUAL

2

EK6IDL Battery-powered Dieless 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, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre­venting 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 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.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

3

EK6IDL Battery-powered Dieless Crimping Tool

IMPORTANT SAFETY INFORMATION

Pinch points:

• Remove battery before changing
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 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.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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.

4

Identification

EK6IDL Battery-powered Dieless Crimping Tool

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

3

7

6

5

4

8

9

1

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

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

2

with the battery charger

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

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

5

Operation

EK6IDL Battery-powered Dieless Crimping Tool

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.

• 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 incor­porating several important features to inform the user
about the current status of the unit. The LED signals in
the following cases:

Pinch points:

• Remove battery before changing
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.

What happens Signal What it means

Flashing light for 2seconds

Constant light for 20seconds
at end of cycle

Tool will not start, and
constant light for 20seconds
when trigger is released

Tool will stop, and constant
light for 20seconds after
trigger is released

Tool will stop, and flashing
light for 20seconds when
trigger is released

Battery is inserted in tool

Battery charge is below
17V at beginning of cycle

Battery charge is below
16V at beginning of cycle

Battery voltage drops
below 13V during cycle

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.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

6

Operation (cont’d)

EK6IDL Battery-powered Dieless Crimping Tool

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.

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.

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.

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.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

7

EK6IDL Battery-powered Dieless Crimping Tool

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

Refer to the

“Connector Table”
and model numbers of appropriate connectors and the
number of crimps required.

connectors listed here.

Connector Table

(NOT for use with flex, navy or welding wire)

Copper Connector Type

Copper Splices

Copper Lugs

* Number of

Crimps

* 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

Copper Cable Size:

8 AWG–600 kcmil

**

Anderson Blackburn

VHSS

VHS

VHCS
VHCL

1 1 1 1 1 1 1 1

CSP

CU

CTL

CTL-L

LCN

®

Burndy ILSCO Panduit T & B

YS-L

YS

YA, YA-L, YA-2L

YA-2LN, YA-2N

YA-L-TC, YA-L-2TC

YA-2TC, YAZ

YAZ-2N, YAZ-2TC

CT

CTL

CLN, CLW, CSW
CRA, CRB, CRC

CRA-L, CRB-L

CRA-2L
CRB-2L
CRC-2L

SCSS

SCS

SCL, SCH

LCAS

LCA
LCB

LCD, LCC

LCAN

for the brand names

54506 to 54528
54806 to 54828

54106 to 54128
54206 to 54228

54906BE to

54928BE

54854BE to

54882BE

Penn­Union

BCU

BBCU

BLU

BBLU

**

Tyco (AMP)

—

1099898-2 to
1-1099898-5
1099899-2 to
1-1099899-9
1099939-1 to
1-1099939-5

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

8

Maintenance

EK6IDL Battery-powered Dieless 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
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.

Warranty Claims

Send tool to Greenlee CTSC Service Center.

Relief valve adjustments must be done by an
authorized service center.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

9

Troubleshooting

EK6IDL Battery-powered Dieless 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 oftool.

Tool battery contacts damaged. Reform contacts.

Tool components worn or
damaged.

Motor is inoperative. Low or uncharged battery. Try known charged battery. Inoperative battery

Broken switch components. Return tool to a Greenlee Authorized Service

Motor runs but tool will not
complete a cycle.

Oil level low. Return tool to a Greenlee Authorized Service

Air in hydraulic system. Pull trigger and hold retract button simultane-

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.

Return tool to a Greenlee Authorized Service
Center.

may be discharged or may have reached life
expectancy.

Center.

Center.

ously. 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 simultane-

ously to warm oil. Store tool in warm area.

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.

Note: For warranty claims, send tool to Greenlee CTSC Service Center.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

10

EK6IDL Battery-powered Dieless 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.

www.greenlee.com

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