Thomas & Betts Gator EK22GL - Manual (Page 12)

EK22GL Battery-powered, High-speed Crimping Tool
Greenlee Textron / Subsidiary of Textron Inc. 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
Assembly
Motor, Gearbox, and Bearing
1. Install two fillister head screws (112) into the spacer
(not numbered) and motor (90). Tighten the screws.
2. Install four screws (not numbered) into the gear
housing (94). Tighten the screws.
3. Install four screws (93) into the mounting block (109)
and gear housing (94). Tighten the screws.
4. Replace the grooved ball bearing (101) and snap
ring (100) subassembly.
5. Replace the eccentric (103). Use a fiber mallet to tap
the eccentric onto the shaft. Replace the ball bearing
(91).
6. Align the end cap (102). Use a fiber mallet to tap the
cover until it is flush on the mounting block (109).
Install two screws (92).
7. Align the gear housing/motor subassembly so that
the pump piston (152) extends through the mounting
block (109) and makes contact with the grooved
bearing (101). Locate and start the screws (108)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert the pump piston (152) into the pump housing.
2. Insert the seal (122) and unloading valve assembly
into the pump housing. Grasp the needle valve
subassembly by the pressure relief (126) and twist it
several turns clockwise. Stop when the piece of tape
is facing up.
3. Assemble the pump piston (150), valve stem (156),
washer (153), spring (155), and screw plug (151). Be
sure to replace the sealing washer (154). Torque the
screw plug (151) to 101 Nm (75 ft-lb).
4. Install the release lever (107) so that the forked end
engages the unloading valve subassembly between
the pressure relief (126) and the support ring (127).
Install the screw (99) and washer (104).
5. Insert the threaded bushing (79) and feed tube sub-
assembly (77, 78, 82). Screw in until snug.
6. Install the reservoir (74). Slip the O-ring (80) over the
reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing.
7. Insert the plug (76) into the reservoir.
Main Components
1. Remove the protective plastic bag from the
electronics subassembly. Insert the LED into the
LED bushing (59).
2. Lay the gear housing/motor subassembly into the
right half of the housing. 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 the case. Be sure that the wires
will not be pinched.
4. Guide the wires for the battery clip so that the
battery wires lay on top of the electronics box; install
the battery clip so that the red wire is upward.
5. Install the trigger cover (53) and plug (60). Press and
release the trigger to be sure that it operates freely.
6. Locate the right housing half on top of the left
housing half. Check for pinched wires.
7. Install the housing screws (51, 56, 57, 58).
Note: The handle screw (51) must engage the nut
(52).
8. Install the piston (15).
9. Install the spring (18).
10. Replace the front head assembly. Twist the head
base (25) until it stops; back off 3/4 of a turn and
tighten the screws (24). Be sure that the crimping
head assembly rotates freely approximately 350
°
.
11. Install the die holder assembly (28). Insert the pin
(37) through the ram.
12. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the fill plug
(76) and fill the reservoir with hydraulic oil.
13. Install the battery.
14. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir with hydraulic
oil. Replace the fill plug (76).
15. Replace the tank cover and tank cover screws.