Assembly - Greenlee GATOR EK06AT Instruction Manual

Service (cont'd)

Assembly

Motor, Gearbox and Bearing
1. Install two fillister head screws (27) into spacer (not
numbered) and motor (24). Tighten screws.
2. Install four screws (not numbered) into gear housing
(28). Tighten screws.
3. Install four screws (29) into mounting block (8) and
gear housing (28). Tighten screws.
4. Replace grooved ball bearing (31) and snap ring
(30) subassembly.
5. Replace eccentric (51). Use a fiber mallet to tap
eccentric onto shaft. Replace ball bearing (50).
6. Align end cap (53). Use a fiber mallet to tap cover
until it is flush on mounting block (8). Install two
screws (54).
7. Align gear housing/motor subassembly so that the
pump piston (49) extends through the mounting
block (8) and makes contact with the grooved
bearing (31). Locate and start the three screws (7)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert pump piston (49) into pump housing.
2. Insert seal (4) and unloading valve assembly into
pump housing. Grasp needle valve subassembly by
the pressure relief (11) and twist it several turns
clockwise. Stop when the mark or piece of tape is
facing up.
3. Assemble pump piston (45), valve stem (44),
spring (43) and screw plug (41). Be sure to replace
sealing washer (45). Torque screw plug (41) to
101 Newton-meters (75 foot-pounds).
4. Install release lever (19) so that the forked end
engages the unloading valve subassembly between
the pressure relief (11) and the support ring (12).
Install screw (15) and washer (57).
5. Insert threaded bushing (37) and feed tube sub-
assembly (34, 35 and 36). Screw in until snug.
6. Install reservoir (17). Slip the O-ring (38) over the
reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing. Insert the
plug (16) into the reservoir.
Greenlee Textron / Subsidiary of Textron Inc.
EK06AT and EK06ATC
Main Components
1. Remove the protective plastic bag from the elec-
tronics subassembly. Insert the LED (218) into its
bushing (218).
2. Lay the gear housing/motor subassembly into the
right half of the housing (216). Insert the circuit
board into the circuit board slot, so that the wires
and chip face in the direction of the trigger.
3. Lay the wires into case. Be sure that the wires
will not be pinched. Guide the wires for the battery
clip so the battery wires lay on top of the electronics
box; install the battery clip so the red wire is upward.
4. Install the trigger (209) and trigger lock (210).
Depress and release the trigger and slide the trigger
lock to be sure that they operate freely.
5. Locate the right housing half (206) on top of the left
housing half (216). Check for pinched wires.
6. Install the housing screws (203, 204, 205 and 212).
Note: Handle screw (212) must engage the nut
(213).
7. Install the piston (223).
8. Install the spring (222) and sleeve (224). Assemble
pin (225) into piston (223) and yoke assembly (102).
9. Set the pump block (1) into the bottom half of the
crimping head. Lay the top half of the crimping head
onto the unit. Assemble with screws (106, 115 and
116).
10. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the fill plug
(16) and fill the reservoir with hydraulic oil.
11. Install the battery (219).
12. Squeeze the trigger while depressing the release
lever for 45 – 60 seconds. Fill the reservoir with
hydraulic oil. Replace the fill plug (16).
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