GATOR™ LS60 Battery-Powered Punch Driver
Greenlee Textron / Subsidiary of Textron Inc.
18
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Motor, Gearbox and Bearing Reassembly
1.
Install two Fillister head screws (83) into spacer and
motor (39). Tighten screws.
2.
Install four screws into gearbox (40). Tighten screws.
3.
Install four screws (77) into mounting block (3) and
gearbox (40). Tighten screws.
4.
Replace grooved ball bearing (47) and retaining ring
(56) subassembly.
5.
Replace eccentric (17). Use a fiber mallet to tap
eccentric onto shaft. Replace ball bearing (46).
6.
Align end cap (2). Use a fiber mallet to tap cover
until it is flush on mounting block (3). Install two
screws (76).
7.
Align gear housing/motor subassembly so that the
pump piston (14) extends through the mounting
block (3) and makes contact with the grooved ball
bearing (47). Locate and start the three screws (81)
through the mounting block and into the pump
housing. Tighten the screws.
8.
Install release lever (15) so that the forked end
engages the needle valve subassembly between
the pressure relief (5) and the plug (6). Install
screw (82).
Pump Reassembly
9.
Insert pump piston (14) into pump spring (55). Insert
piston and spring into pump housing.
10. Insert O-ring (42) and needle valve subassembly
into pump housing. Grasp needle valve subassembly
by the plug (6) and twist it several turns clockwise.
Stop when the mark or piece of tape, placed on the
relief during disassembly, is facing the screw hole.
Sight down the screw hole; find the dimple that the
screw (76) made in the relief (5). Align this dimple at
the center of the screw hole. Insert screw (75) and
tighten until snug against relief (5).
11. Insert threaded bushing (53) and feeding tube
subassembly (10, 11, 19 and 59). Screw in until
snug.
12. Install reservoir (4). Slip the O-ring (49) over the
reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing.
13. Insert the plug (16) into the reservoir.
Reassembly
Final Reassembly
14. Remove the protective plastic bag from the elec-
tronics subassembly. Insert the LED into the LED
hole.
15. Lay the gear housing/motor subassembly into the
right half of the housing (235). Insert the circuit
board into the circuit board slot, so that the wires
and chip face in the direction of the trigger.
16. 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 up-
ward.
17. Install the trigger (227) and trigger lock (228).
Depress and release the trigger and slide the trigger
lock to be sure that they operate freely.
18. Locate the left housing half (224) on top of the right
housing half (235). Check for pinched wires.
19. Install the housing screws (221, 222, 223 and 230).
Note: Handle screw (230) must engage the nut
(231).
20. Install the piston (201) and compression spring
(205).
21. Replace the punching head assembly. Screw the
ram housing (202) on until it stops; back off 3/4 of a
turn and tighten the screws (209). Be sure that the
ram housing rotates freely approximately 350
°
.
22. Rotate the ram housing until the three M4 threaded
holes in the piston are aligned with the three
∅
.18
(4.5mm) holes in the ram housing. Install the three
spacers (204), ram (203), and three screws (206).
Tighten the screws.
23. Clamp the punching head assembly into a vise with
the reservoir plug facing upward. Remove the fill
plug (16) and fill the reservoir with hydraulic oil.
24. Install the battery (238).
25. Squeeze the trigger while depressing the release
lever for 45–60 seconds. Fill the reservoir with
hydraulic oil. Replace the fill plug.
26. Replace the reservoir cover (233) and reservoir
cover screws (234).
