Disassembly - Greenlee GATOR CK1240 Instruction Manual

Disassembly

Main Components
1. Loosen the screw (28). Remove the screw (35) and
stop (36).
2. Unscrew and remove the head assembly.
3. Remove the piston (8). Replace the piston O-ring (6)
and piston backup ring (7).
4. Unscrew two tank cover screws (52) and remove the
tank cover.
5. Remove the hydraulic reservoir plug (76) and drain
the hydraulic fluid.
6. Reinstall the plug.
7. Remove the remaining housing screws (52).
8. Remove the housing half.
9. Remove the switch cover (51) and spring (56).
10. Lift the pump/motor assembly and circuit card from
the housing half.
11. Slide a plastic bag over the circuit card and elec-
tronic subassemblies. Tape the bag shut to protect
the subassemblies from hydraulic oil and other
contamination.
12. Unscrew the shoulder bolt (99) and remove the
release lever (107).
13. Remove screws (108) and separate the gear
housing/motor subassembly from the pump housing.
Pump
1. Use a hooked tool to remove the reservoir O-ring (80).
Gently tug it over the reservoir.
2. Remove the reservoir (74).
3. Remove the pump piston (152).
4. Remove the screw plug (151), washer (153), pump
piston (150), valve stem (156), and spring (155).
Replace the sealing washer (154).
5. Use a piece of tape to mark the side of the relief
that is facing up. (This is a reference point for
reassembly.) Remove the unloading valve by
unscrewing the plug (126).
6. Remove the feeder tube subassembly by unscrew-
ing the feeder tube (78). Replace the oil filter (77).
Remove metal chips from the magnet (82).
7. Remove the threaded bushing (72) and replace the
O-ring (73).
Greenlee / A Textron Company
CK1240 and CK1240C Crimping Tools
Motor, Gearbox, and Bearing
1. Remove the tamper-proof paper seal (96).
2. Remove two screws (92). Remove the end cap
(102).
3. Apply pressure evenly at three points around the
ball bearing (91) and gently pry the bearing up to
remove it.
4. Remove the eccentric (103), grooved ball bearing
(101), and snap ring (100) subassembly from the
shaft.
5. Remove four screws (93). Remove the mounting
block (109) from the gear housing (94).
6. Use a snap-ring removal tool to remove the snap
ring (100).
7. Unscrew four bolts (not numbered) and hex nuts
(97) from the gear housing (94). Separate the gear
housing from the motor flange (110). Unscrew two
flat head screws (112) to separate the flange from
the motor (90).
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4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070