Disassembly/Reassembly - Greenlee GATOR EK1240K Instruction Manual

Disassembly
1. Remove battery.
2. Remove set screw (104) and bolt (123) and stop
(122).
3. Unscrew and remove crimping head assembly.
4. Remove ram (112) and spring holder assembly
(120,121,124,125,126).
5. Remove cylinder (218). Replace the piston O-ring
(217) and piston back-up ring (216).
6. Unscrew two tank cover screws (205) and remove
tank cover.
7. Remove the hydraulic reservoir plug (16) and drain
hydraulic fluid.
8. Reinstall plug.
9. Remove the remaining housing screws (206,204,
214,212).
10. Remove left housing half.
11. Remove switch cover (209) and trigger lock (210).
12. Lift pump/motor assembly and circuit card from right
housing half. Lift LED from its bushing (208).
13. 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.
14. Unscrew shoulder bolt (15) and remove release
lever (18).
15. Remove cap screws (7) and separate the gear
housing/motor subassembly from pump housing.
16. Use a hooked tool to remove the reservoir O-ring
(38). Gently tug it over the reservoir.
17. Remove the reservoir (17).
18. Remove pump piston (49). Replace the O-ring (46).
19. Remove screw plug (39), spring (41), valve stem
(40), pump piston (43) and sealing washer (42).
20. Use a marker or piece of tape to mark the side of
the relief (11) that is facing up. This mark or piece of
tape will later be used when installing the unloading
valve subassembly. Remove unloading valve
subassembly by unscrewing the plug (11).
21. Remove feeder tube subassembly by unscrewing
feeder tube (37). Replace the oil filters (34). Re-
move magnet (36) and clean off metal chips.
22. Remove threaded plug (47) and O-ring (48).
Replace O-ring and reassemble.
Greenlee Textron / Subsidiary of Textron Inc.
EK1240K and EK1240KC
Motor, Gearbox and Bearing Disassembly
23. Remove tamper-proof paper seal (53).
24. Remove two screws (55). Remove end cap (54).
25. Apply pressure evenly at three points around the
ball bearing (31) and gently pry the bearing up to
remove it.
26. Remove eccentric (52), grooved ball bearing (31),
and snap ring (30) subassembly from shaft.
27. Remove four screws (29). Remove mounting block
(8) from gear housing (28).
28. Use a snap-ring removal tool to remove the snap
ring (30).
29. Unscrew four bolts (not numbered) from the gear
housing (28). Separate gear housing from spacer
(not numbered). Unscrew two fillister head screws
(27) to separate spacer from motor (24).
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