Greenlee 976-22 Manuale utente
INSTRUCTION MANUAL
99991381 © 2006 Greenlee Textron Inc. IM 1036 REV 17 5/06
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
976-22 and 980-22
Hydraulic Power Pumps
Serial Codes YD and ABZ
Greenlee / A Textron Company 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual ................................................... 2
Other Publications .......................................................... 2
Important Safety Information ...................................... 3–4
Specifications ................................................................. 5
Setup .............................................................................. 6
Operation ........................................................................ 7
Maintenance ............................................................... 8–9
Troubleshooting ...................................................... 10–11
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron shall not be liable for damages resulting
from misapplication or misuse of its products.
Mobil DTE is a registered trademark of Mobil Oil Corporation.
KEEP THIS MANUAL
Description
Greenlee 976-22 and 980-22 Hydraulic Power Pumps
are electrically powered, two-stage pumps that develop
a maximum of 690 bar (10,000 psi). These pumps are
intended to provide hydraulic power for an accessory
with a single-acting ram such as a Greenlee conduit
bender or cable cutter.
These pumps have a factory-set internal pressure relief
valve.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This manual and any
markings on the tool provide information for avoiding
hazards and unsafe practices related to the use of this
tool. Observe all of the safety information provided.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee tools:
976-22 Hydraulic Power Pump (Serial Code YD)
980-22 Hydraulic Power Pump (Serial Code ABZ)
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge.
Other Publications
Service Manual: 99945949
Fill unit with hydraulic oil before
operating pump.
Failure to fill unit with oil will result
in damage to the pump.
Do not discard this product or throw away!
For recycling information, go to www.greenlee.
com.
Greenlee / A Textron Company 3 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
IMPORTANT SAFETY INFORMATION
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury or death.
Do not use this pump in a hazardous
environment. Hazards include
flammable liquids, gases, or other
materials. Using this pump in a
hazardous environment can result
in a fire or explosion.
Failure to observe this warning will
result in severe injury or death.
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, defined below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
SAFETY
ALERT
SYMBOL
Do not alter the internal high-pressure relief valve
setting. Altering this setting will change the maximum
pressure the pump can develop, which can cause a
component failure. Nearby personnel can be injured
by flying components and hydraulic oil.
Failure to observe this warning will result in severe
injury or death.
Do not connect the pump to any system or system
component other than those supplied by Greenlee.
Other manufacturersʼ components may not with-
stand the maximum pressure and may fail. Nearby
personnel can be injured by flying components and
hydraulic oil.
Failure to observe this warning will result in severe
injury or death.
Greenlee / A Textron Company 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
IMPORTANT SAFETY INFORMATION
Note: Keep all decals clean and legible, and replace
when necessary.
Inspect pump, hoses, couplers, and fittings for
wear or damage. Replace worn, damaged, or
missing components with Greenlee replacement
parts. Worn or damaged components can fail,
resulting in injury.
Failure to observe this warning could result in
severe injury or death.
• The pump is heavy and requires two persons to lift.
Improper lifting can result in injury.
• Do not use hose or cord to pull, lift, or carry the
equipment. Misuse will damage the hose or cord.
Failure to observe these precautions may result in
injury or property damage.
Make sure all hose fittings are properly seated
before starting the pump. Incomplete connections
may not allow the accessoryʼs ram to retract after
the hydraulic operation is finished.
Electric shock hazard:
• Do not expose power tools to rain.
• Do not immerse the pendant
switch in water or other liquid.
Failure to observe these warnings
could result in severe injury or death.
Skin injection hazard:
High pressure oil easily punctures
skin causing serious injury, gangrene,
or death. If injured, seek medical
help immediately to remove oil.
• Do not use fingers or hands to
check for leaks.
• Depressurize hydraulic system
before servicing or disconnecting
the hose.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
flying debris or hydraulic oil.
Fill unit with hydraulic oil before
operating pump.
Failure to fill unit with oil will result
in damage to the pump.
Greenlee / A Textron Company 5 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
Specifications
Motor
Voltage ........................................................................................................ 220 VAC
Frequency ........................................................................................................ 50 Hz
Current
976-22 ............................................................................................................3.8 A
980-22 ...............................................................................................................9 A
Power
976-22 ......................................................................................................... 875 W
980-22 ....................................................................................................... 2100 W
Revolutions per Minute ......................................................................................3000
Pump Output
Power
976-22 ............................................................................................1/2 hp (373 W)
980-22 .......................................................................................1-1/2 hp (1119 W)
Maximum Hydraulic Pressure
(pressure relief valve setting) .................................................... 690 bar (10,000 psi)
Hydraulic Fluid Capacities
Full
976-22 ................................................................................................... 5.7 l (6 qt)
980-22 ................................................................................................... 7.6 l (8 qt)
Usable
976-22 ................................................................................................... 2.8 l (3 qt)
980-22 ................................................................................................... 5.7 l (6 qt)
Greenlee Hydraulic Oil Viscosity .......................30 cSt at 40 °C (150 SSU at 100 °F)
6 cSt at 100 °C (46 SSU at 210 °F)
Viscosity Index .....................................................................................................145
Pour Point ........................................................................................ –40 °C (–40 °F)
976-22 Typical Performance
Pressure Volume
0 ............................................................................................3.4 l/min (208 in3/min)
6.9 bar (100 psi) ....................................................................3.25 l/min (200 in3/min)
345 bar (5000 psi) ...................................................................0.26 l/min (16 in3/min)
552 bar (8000 psi) ...................................................................0.25 l/min (15 in3/min)
980-22 Typical Performance
Pressure Volume
0 ............................................................................................3.4 l/min (208 in3/min)
6.9 bar (100 psi) ....................................................................3.25 l/min (200 in3/min)
345 bar (5000 psi) ..............................................................0.76 liter/min (47 in3/min)
552 bar (8000 psi) ...................................................................0.73 l/min (45 in3/min)
Greenlee Hydraulic Oil (Mobil DTE® 13M)
Part No. 905 1059.3 / 4016GB ......................................................................1 gallon
Part No. 905 0806.8 / 4017GB ....................................................................... 1 quart
Greenlee / A Textron Company 6 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
Setup
Hydraulic Connection
1. Clean all couplers, threaded fittings, ports, and the
area around all ports.
2. Remove any dust plugs from the couplers.
3. Hand-tighten all couplers firmly (until all threads are
fully engaged). Do not use tools.
Grounding Instructions
This tool must be grounded. In the event of a malfunc-
tion
or breakdown, an electrical ground provides a path
of least resistance for the electric current. This path of
least resistance is intended to reduce the risk of electric
shock.
This toolʼs electric cord has a grounding conductor and
a grounding plug as shown. Do not modify the plug.
Connect the plug to a corresponding 15 A GFCI-
protected receptacle that is properly installed and
grounded in accordance with all national and local codes
and ordinances.
Do not use an adapter.
Electric shock hazard:
• Do not modify the plug provided
with the tool.
• Connect this tool to a grounded re-
ceptacle on a 15 A GFCI-protected
circuit.
Failure to observe these warnings
could result in severe injury or death.
Extension Cord Specifications
Cord Diameter (minimum)
976-22 ............................................ 1.5 mm2 (14 AWG)
980-22 ............................................ 2.5 mm2 (12 AWG)
Cord Length (maximum) ...............................30 m (100 ft)
Use only three-wire extension cords. Use of an
inadequate extension cord will cause the motor to stall.
Greenlee / A Textron Company 7 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
Note: To prevent leakage, this pump was shipped with
an unvented plug installed in the reservoir fill hole. This
plug must be replaced with the attached vented plug
before use. Failure to replace the unvented plug will
cause poor performance.
Note: Starting the motor without a tool attached to
the pump will cause the pump to immediately build an
internal pressure of 690 bar (10,000 psi). If this happens,
shut off the pump and turn the release valve to AUTO
RELEASE to release the hydraulic pressure.
1. Fill with oil provided before attempting to operate the
pump the first time.
2. Move the release valve lever to the
AUTO RELEASE position.
3. The oil level should be within 25 mm (1 inch) of the
top of the reservoir.
If the oil level is too low, refer to “Adding Oil” in the
“Maintenance” section for instructions.
4. Place the release valve lever in the desired position:
• AUTO RELEASE: Ram stops and then retracts
when the hand switch or foot switch is released.
• MANUAL RELEASE: Ram stops but does
not retract when the hand switch or foot switch
is released.
5. Press the hand switch or foot switch to advance
the hydraulic ram. When finished, release the hand
switch or foot switch.
Note: If the release valve lever is in the MANUAL
RELEASE position, the ram will not retract.
To retract the ram, rotate the release valve lever to
the AUTO RELEASE position.
Skin injection hazard:
High pressure oil easily punctures
skin causing serious injury, gangrene,
or death. If injured, seek medical
help immediately to remove oil.
• Do not use fingers or hands to
check for leaks.
• Depressurize hydraulic system
before servicing or disconnecting
the hose.
Operation
Procedure for depressurizing the hydraulic system:
1. Disconnect the pump from the power source.
2. Rotate the release lever to AUTO RELEASE
and allow the ram to retract fully.
3. Disconnect the hose slowly to release any
trapped pressure.
Fill unit with hydraulic oil before
operating pump.
Failure to fill unit with oil will result
in damage to the pump.
Greenlee / A Textron Company 8 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
Maintenance
Procedure for depressurizing the hydraulic system:
1. Disconnect the pump from the power source.
2. Rotate the release lever to AUTO RELEASE
and allow the ram to retract fully.
3. Disconnect the hose slowly to release any
trapped pressure.
Every Time the Pump Is Used
• Check the oil reservoir level. The oil level should be
approximately 25 mm (1 inch) from the top of the
reservoir. If the oil level is low, refer to “Adding Oil” in
this section of the manual.
• Examine the condition of the hose, connectors,
and O-rings for deterioration, wear, or other damage.
Replace any missing or damaged components.
• Check the condition of all electrical cords, plugs,
and connectors.
• Listen for unusual noises and observe the operation
of the pump for changes in performance. Either
situation may indicate that maintenance or repairs are
necessary.
Periodically
• Examine the hydraulic oil for changes in color or
viscosity, and the presence of dirt or other contamina-
tion.
• Occasionally check the oil temperature after the pump
is operated. The recommended operating temperature
is 38 °C to 50 °C (100 °F to 125 °F).
Cleaning
• Periodically clean the exterior of the pump and motor.
Use a vacuum cleaner to clean the ventilation
openings.
• Clean the area around the reservoir vent, and be sure
the vent breather hole is open.
• Keep all hose connections clean. Use protective caps
or plugs when couplers are not in use.
Oil Condition
Visual inspection of the oil may be used as a guide to
determine the need to replace the oil. A change in
appearance, such as darkening or thickening, indicates
a need for replacement. The continued use of oil after it
should be replaced causes accelerated wear of system
components and voids the warranty.
Adding Oil
1. Place the control lever in the AUTO RELEASE
position.
2. Unplug the electrical cord from the power source.
3. Thoroughly clean the area around the fill hole.
4. Remove the vented reservoir plug.
5. Use Greenlee hydraulic fluid or an equivalent high-
grade light hydraulic oil. Refer to the “Specifications”
section of this manual to determine the correct type
of hydraulic oil.
6. Pour the oil through a clean funnel with a filter
screen.
7. Add oil until the oil level is 25 mm (1 inch) from the
top of the reservoir cover.
Do not use brake fluid. Brake fluid will ruin the seals.
Greenlee / A Textron Company 9 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
Draining and Flushing the System
Note: Thoroughly clean the pump exterior before
removing the reservoir.
1. Remove the reservoir cover screws.
2. Remove the pump system from the reservoir.
Note: Be careful not to damage the cover gasket,
inlet strainer, or relief valve when removing the
pump.
3. Clean the interior of the reservoir and fill with clean
kerosene. Do not use solvents. Rinse the inlet
strainer.
4. Place the pump system into the reservoir and
replace the four cover screws.
5. Connect a hose to the pump as usual. Insert
the other end of the hose into the pump reservoir
at the fill hole.
6. Run the pump for several minutes. While the pump
is running, rotate the control lever between MANUAL
RELEASE and AUTO RELEASE several times.
Start and stop the pump several times to cycle the
pilot-operated valve.
7. Remove the hose and remove the pump assembly
from the reservoir. Drain and clean the reservoir
interior. Allow the reservoir to dry. Drain the hose.
8. Reassemble the pump system.
9. Refill the reservoir as instructed under “Adding Oil”
in this section of the manual.
Motor Maintenance
Disconnect the pump from the power source before
servicing or cleaning the motor. The exposed motor
bearings and shaft should be cleaned periodically.
Lubrication
Lubricate the motor according the motor manufacturerʼs
instructions, which are on the nameplate or the terminal
box cover.
Maintenance (contʼd)
Erratic performance may indicate air in the hydraulic
fluid.
1. Remove the ram from the accessory (conduit bender
frame, cable cutter, etc.).
2. If possible, position the pump so that it is located
higher than the ram. This will allow air to travel up
the hydraulic hose to the pump reservoir.
3. Place the ram in a vertical position with the hose
coupler upward.
4. Rotate the control lever counterclockwise
(to MANUAL RELEASE).
5. Start the pump and, using the ram scale as a
reference, advance the ram 3/4 of its stroke.
Stop the pump. Do not overextend the ram.
6. Rotate the control lever clockwise (to AUTO
RELEASE). The ram will retract, forcing any air
out through the hose, into the pump reservoir, and
through the vented plug.
7. Check the oil level of the reservoir. Add oil if
necessary.
Purging (Bleeding) Air
When purging air from the system:
• Do not advance the ram more than 3/4 of its
stroke. Overextending the ram allows hydraulic
fluid to leak out, and the ram may damage the
O-rings when it retracts.
• Do not restrict the ram travel to run the pump up
to full pressure.
Failure to observe these precautions may result in
injury or property damage.
Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
976-22 and 980-22 Hydraulic Power Pumps
Troubleshooting
Repair work must be done by qualified personnel familiar
with this equipment.
If possible, use a hand pump to apply back pressure
when checking for leaks.
How to use this table
If your hydraulic pump does not operate properly, find
the description of the problem under the “Problem”
column. Read the “Probable Cause” and the “Possible
Remedy.” Begin with the solution listed first, and proceed
through all of the solutions until the problem is solved.
Probable Cause
Problem Possible Remedy
Motor does not start. Plug the electric cord into a properly rated
power source. Unplug the cord and inspect the
contacts. Clean the contacts if necessary.
No power to motor.
Motor does not start
under load. Unplug the cord and check the power source
with a voltmeter. The voltage should be
220 VAC (±10%).
Voltage supplied to motor is too low.
Refer to the “Extension Cord Specifications”
in the “Setup” section of this manual.
Current rating of extension cord is
too low.
Motor starts, but stops
when it encounters a
load.
Unplug the cord and check the power source
with a voltmeter. The voltage should be
220 VAC (±10%).
Voltage supplied to motor is too low.
Refer to the “Extension Cord Specifications”
in the “Setup” section of this manual.
Current rating of extension cord is
too low.
Let the motor cool. Do not run the motor
continuously in a hot environment.
Motor is overheated.
Ram does not advance.
Ram advances slowly.
Ram does not advance
completely. Add oil per the instructions in the “Maintenance”
section of this manual.
Oil level is too low.
Replace oil with the type recommended in the
“Specifications” section of this manual.
Wrong oil viscosity.
Replace oil with the type recommended in the
“Specifications” section of this manual.
Oil is dirty.
Preheat the oil. Without an accessory con-
nected to the coupler, run the pump to build
pressure and then release. Repeat until the oil
is warm.
Oil is cold.
Remove the strainer and clean with kerosene.The intake strainer is dirty or clogged.
Remove the unvented plug and install the
vented plug.
Unvented plug has not been replaced.
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