Greenlee 776 User manual

INSTRUCTION MANUAL
99949598 REV 4 © 2019 Greenlee Tools, Inc. 2/19
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
776
Ratchet ACSR Cutter

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Description ..................................................................... 2
Purpose of this Manual .................................................. 2
Important Safety Instructions ......................................... 3
Identication................................................................... 4
Specications................................................................. 4
Operation........................................................................ 5
Maintenance
General .................................................................... 6
Cleaning the cutter .................................................. 6
Lubricating the cutter .............................................. 6
Disassembly ................................................................... 7
Assembly
Cutter head.............................................................. 8
Stationary handle..................................................... 9
Movable handle ....................................................... 9
Movable handle to stationary handle .................... 10
Cutter head to stationary handle........................... 10
Cutter head to movable handle ............................. 11
Tighten pivot screws ............................................. 11
Illustration..................................................................... 12
Parts Lists................................................................13-14
Table of Contents
Description
The Greenlee 776 Ratchet Cutter is a non-insulated
cutting tool intended to cut ACSR through 636 kcmil
with steel core diameter less than 0.32".
Specically cuts:
• all 336.4 kcmil and smaller ACSR
• 397.5 kcmil – Brant, Chickadee, Ibis
• 477.0 kcmil – Pelican, Flicker, Hawk
• 566.5 kcmil – Osprey, Parakeet
• 605.0 kcmil – Peacock
• 636.0 kcmil – Kingbird, Swift, Rook
This tool is equipped with berglass handles and rubber
grips to limit operator fatigue.
This tool is not intended to cut guy wire, rebar, or steel rod.
The Greenlee 776 Ratchet Cutter is protected by U.S.
Patent No. 6,766,581.
Purpose of this Manual
This instruction manual is intended to familiarize
personnel with the safe operation and maintenance
procedures for the Greenlee 776 Ratchet Cutter.
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction 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.
KEEP THIS MANUAL
All specications are nominal and may change as design improve-
ments occur. Greenlee Tools, Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
Molykote is a registered trademark of Dow Corning Corporation.
Loctite is a registered trademark of Loctite Corporation.
Safety

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning
could 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,
dened below, indicates the severity of the hazard.
The message after the signal word provides infor-
mation for preventing 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
IMPORTANT SAFETY INFORMATION
• This tool is intended for two-handed opera-
tion. Maintain a rm grip on both handles during
operation.
• Do not cut guy wire or steel rod.
• Do not exceed the rated capacity of this tool.
• Inspect before use. Replace any worn or
damaged parts.
• Do not perform any service or maintenance other
than as described in this manual.
Failure to observe these precautions may result in
injury or property damage.
Pinch points:
Keep hands away from moving
parts.
Wear eye protection when using this
tool. Failure to wear eye protection
could result in serious eye injury
from ying debris.
Keep hands away from closing
blades.
Electric shock hazard:
This tool is not insulated. Do not use
this tool near energized electrical
lines.
Failure to observe this warning could
result in severe injury or death.

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Specifications
Mass/Weight............................................................................................2.8 kg (6.2 lb)
Length ............................................................................................... 505 mm (19.87")
Width
at blades ............................................................................................ 127 mm (5.0")
at handles......................................................................................... 159 mm (6.25")
Thickness .............................................................................................. 68.5 mm (2.7")
Jaw opening (minimum) ......................................................................... 29 mm (1.15")
Handle force at Maximum Capacity......................................................... 267 N (60 lb)
Capacity —cuts ACSR through 636 kcmil with steel core diameter less than 0.32"
Specically cuts:
• all 336.4 kcmil and smaller ACSR
• 397.5 kcmil – Brant, Chickadee, Ibis
• 477.0 kcmil – Pelican, Flicker, Hawk
• 566.5 kcmil – Osprey, Parakeet
• 605.0 kcmil – Peacock
• 636.0 kcmil – Kingbird, Swift, Rook
Identification
Keeper
Stationary
blade
Movable
blade
Speed
pawl
Link
Movable
handle Grips
Stationary
handle
Release
knob
Do not attempt to cut ACSR cable that is not listed, or ACSR cable with a
steel core diameter greater than 0.32".
Failure to observe this precaution may result in damage to the tool.

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Operation
• This tool is intended for two-handed operation.
Maintain a rm grip on both handles when using
this tool.
• Inspect before use. Replace any worn or
damaged parts.
Failure to observe these precautions may result in
injury or property damage.
Electric shock hazard:
This is not an insulated tool.
Contact with live circuits could
result in severe injury or death.
Wear eye protection when using this
tool. Failure to wear eye protection
could result in serious eye injury
from ying debris.
1. Check to see that the release knob is against the link.
2.
Place the cable to be cut between the cutting blades.
3. Open and close the handles until the cable is cut.
Note: The automatic rapid advance mechanism will
advance the movable blade by 3 teeth each time
the handle is opened. The blade advances 1 tooth
for each closing of the handle. The rapid advance
mechanism is spring-loaded to disengage when
maximum leverage is needed to cut the cable.
4. When the cut is complete, the automatic blade
mechanism automatically returns the blade to the
open position and resets the reverse lever to cut
cable.
Note: To open the blade before the cut is complete,
move the release knob away from the link and press
the handles together. The blade spring will return the
blade to the open position.
release knob
engage
link
release knob
disengage
link

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Maintenance
General
Maintain the tool with care. Keep the blades sharp
and the tool clean for better and safer performance.
Follow instructions for lubricating the cutter; lubrication
prolongs the tool life and enables the tool to cut with
less force. Keep grips dry, clean and free from oil and
grease.
Note: The blade lock nut (43) may require tightening
after making several initial cuts on a new or repaired
unit. Always maintain proper adjustment on all pivot
screws. For adjustment procedures, see Assembly—
Tighten pivot screws.
Cleaning the cutter
Blow dirt and/or cable particles out of the ratchet
mechanism with compressed air.
Lubricating the cutter
Close the blades and apply Molykote lubricant or
equivalent between the blades. Lubricate the teeth on
holding pawl (6) and drive pawl (7). Lubricate the four
pivot shoulder screws (13, 16 and 17) and area between
pivoting surfaces. Operate the cutter to spread the
lubricant.
Disassemble, clean, and lubricate the tool if it does not
operate smoothly.
Wear eye protection when using this
tool. Failure to wear eye protection
could result in serious eye injury
from ying debris.
Pinch points:
Keep hands away from moving
parts.
Keep hands away from closing
blades.
Lubrication points
—use Molykote
®

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Disassembly
This tool consists of three subassemblies: the cutter
head, stationary handle, and movable handle sub-
assemblies (see gure).
1. Cutter head assembly: movable blade (1),
stationary blade (2), release lever (3), links (4),
keeper (18), spring cover (10), reverse lever pin (12),
spring (37), bushing (29), return spring (36), shoulder
screw (17) and related hardware.
2. Stationary handle assembly: handle unit (39),
handle plates (5), holding pawl (6), torsion spring
(40), shoulder screw (16) and related hardware.
3. Movable handle assembly: handle unit (38),
handle plates (8 and 9), speed pawl (11), spring
(35), drive pawl (7), shoulder screws (13 and 16) and
related hardware.
The disassembly procedure is divided into sections of
the tool. Disassemble only the section(s) necessary to
complete the repair.
Disassemble the tool on a at, clean surface. Take care
not to lose or damage any parts that may fall free during
disassembly.
Cutter head
1. Open the movable blade to release tension on the
blade return spring (36).
2. Remove two shoulder screws (16) and remove the
cutter head assembly from the handle assemblies.
Note: Holding pawl (6), torsion spring (40), drive
pawl unit (7), washer (22) and spacer (19) may fall
free during disassembly.
3. Remove shoulder screw (17), spacers (27 and 20),
links (4), release lever (3) and bushing (29).
4. Remove screw (15) and separate cover (10) from
stationary blade (2).
5. Remove screw (41) and spring (36).
Stationary handle
6. Remove shoulder screw (13) and movable handle
assembly.
7. Remove two screws (30) and stationary handle
plates (5).
Movable handle
8. Remove two screws (31), left handle plate (8), right
handle plate (9), speed pawl (11) and spring (35).
cutter head
assembly
17
16
13
movable handle
assembly
stationary handle
assembly

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Assembly
Refer to the Exploded View and Parts List for correct
orientation and placement of parts. Inspect and replace
any worn or damaged parts. Wherever the assembly
results in metal-to-metal contact, coat the surfaces with
Molykote or equivalent lubricant.
Cutter head
1. Apply Loctite 680 retaining compound to two dowel
pins (32) and install into movable blade, if necessary.
The dowel pins should be ush with the at side of
the blade. Remove excess Loctite.
2. Apply Loctite 271 thread adhesive to screw (41)
and install screw through end of spring (36) and into
movable blade. Adjust until end of screw is ush
with the angled side of the blade. Allow Loctite to
cure for 10 minutes and remove excess adhesive.
3. Install roll pin (14) into stationary blade (2), if
necessary.
46
(optional)
17
4
29
3
32
25
44
43
10
15
27
4
41
36
20
14
2
28
18
Apply
Loctite 242
Apply
Loctite 271
Apply
Loctite 242
Apply
Loctite 680
1
4. Install end of spring (36) over roll pin (14) and
assemble spacer (25), and cover (10). Apply Loctite
242 thread adhesive to screw (15) and assemble
to stationary blade (2). Roll pin (14) should be ush
with top of cover (10).
5. Install optional screw guide (46) onto shoulder screw
(17) to help guide the screw through components.
6. Lubricate components and assemble shoulder
screw (17), two links (4), bushing (29), reverse
lever (3), movable blade (1), stationary blade (2),
spacer (20), cover (10), link (4), spacer (27)—with
counterbore toward link. Remove guide (46) if
used and install lock nut (43). Tighten lock nut so
gap between blades does not exceed .004 inches.
Tighten set screw (44).
7. Apply Loctite 242 thread adhesive to screws (28)
and install screws through keeper (18) and into
stationary blade (2).

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
slot
chamfer 38
9
13
16
30
5
39
Stationary handle
8. Assemble handle plates (5) to handle unit (39),
but do not tighten hex screws (30).
9. Insert shoulder screws (13 and 16) to align handle
plates (5) and tighten hex screws (30) to 170-190
in-lb. Remove shoulder screws.
11
33
31
8
35
34
38
9
.20"
Movable handle
10. Assemble right and left handle plates (8 and 9) to
handle unit (38), but do not tighten hex screws (31).
Orient handle plates so slotted hole is opposite the
chamfer in the handle adapter.
15. Insert shoulder screws (13 and 16) to align handle
plates and tighten hex screws (31) to 170-190 in-lb.
Remove shoulder screws.
11. Install roll pin (34) into right and left handle plates.
12. Install roll pin (33) into speed pawl (11), if necessary.
The roll pin should protrude .20 inches from each
side of the speed pawl.
13. Install spring (35) between handle plates.
14. Spread the right and left handle plates and install
speed pawl so the roll pin ts into the slot in the
handle plates. Use the speed pawl to compress
spring (35).
Assembly (continued)

776 Ratchet ACSR Cutter
Greenlee Tools, Inc. 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Assembly (continued)
Movable handle to stationary handle
16. Install movable handle assembly between the
stationary handle plates and align 3/8" pivot holes.
17. Install optional screw guide (46) onto shoulder screw
(13) to help guide the screw through components.
18. Lubricate shoulder screw (13) and install it through
the handle plates (5 and 8), handle plates (9 and
5) and spacer (26). Remove guide (46) if used and
install lock nut (23).
Cutter head to stationary handle
19. Install torsion spring (40) onto holding pawl (6)
and locate them between the handle plates on the
stationary handle (39) as shown.
20. Install head assembly between handle plates on the
stationary handle and around the holding pawl (6).
21. Install optional screw guide (47) onto shoulder screw
(16) to help guide the screw through components.
22. Lubricate shoulder screw (16) and install it through
link (4), handle plate (5), torsion spring (40), holding
pawl (6), stationary blade (2), second handle plate (5),
cover (10) and spacer (19). Remove guide (47) if used
and thread on lock nut (24), but do not tighten.
Note:
Ends of torsion spring should be
against handle and pawl as shown.
stationary handle
assembly
movable handle
assembly
9
8
23
26
5
5
46
(optional)
13
2
47
(optional)
4
16
40
5
39
24
19
10
6
5