Greenlee 940-PS Guide

OPERATION, SERVICE AND PARTS
INSTRUCTION MANUAL
999 6464.3 © 1997 Greenlee Textron IM 808 REV 1 6/97
Read and understand this material before
operating or servicing this tool. Failure to
understand how to safely operate the tool
could result in an accident causing serious
injury or death.
HYDRAULIC POWER PUMPS
940-PS Series

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Introduction
The 940-PS is a high pressure hydraulic power pump
which is simple to operate, lightweight, constructed with
extreme durability and is portable.
The pump is controlled by a three-position pendant
switch which has momentary contact in the forward
position, OFF in the center position and sustained
contact in the opposite position.
Safety is a critical factor in the design of Greenlee equipment. The best program starts with a safety-conscious
operator. The information highlighted in this bulletin describes operating practices for the benefit of the workers
who will use our equipment in their daily jobs. Comments from users are appreciated.
The symbol above is used to call your attention
to instructions concerning your personal safety.
Watch for this symbol. It points out important safety
precautions. It means “ATTENTION! Become alert!
Your personal safety is involved!” Read the
message that follows and be alert to the possibility
of personal injury or death.
Hazards or unsafe practices which, if not avoided, COULD
result in minor personal injury or property damage.
Hazards or unsafe practices which, if not avoided, COULD
result in severe personal injury or death.
Immediate hazards which, if not avoided, WILL result in
severe personal injury or death.
SAFETY
ALERT
SYMBOL
A person who has not read and does not understand all
operating instructions is not qualified to operate this tool.
Failure to read and understand safety instructions may
result in injury or death.
The 940-PS also features a supercharger which provides
low pressure / high volume delivery for rapid advance of
the ram to the work and automatic changeover to low
volume / high pressure delivery when ram pressure
exceeds 200 psi. The pump is a one-piston radial-type
capable of developing 10,000 psi. The pumping unit is
protected against excessive pressure by a safety valve
set at 10,000 psi.

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
SAVETHESE INSTRUCTIONS
Additional copies of this manual are available upon request at no charge.
IMPORTANT SAFETY INSTRUCTIONS
• Do not connect the pump to any system or
system component other than those supplied by
Greenlee and rated at less than 10,000 psi
(68,950 kPa).
• Do not alter the internal high-pressure relief
valve setting.
• Do not use this pump in a hazardous environment.
Hazards include open flame and flammable liquids
or gases.
Failure to observe these warnings will result in
severe injury or death.
Electric shock hazard:
• Do not expose power tools to rain.
• Do not immerse the pendant
switch in water or other liquid.
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 disconnecting the hose.
•I nspect pump, hoses, couplers and fittings for wear
or damage. Replace worn, damaged or missing
components with Greenlee replacement parts.
• Do not twist, kink, curl, paint or cut the
hydraulic hoses.
• Wear eye protection when operating this
equipment.
• Disconnect the pump from the power supply,
rotate the release valve lever to AUTO RELEASE,
and disconnect the hose from the ram and the
pump before performing any service.
Failure to observe these warnings could result in
severe injury or death.
• The pump is heavy, weighing up to 75 lbs. Follow
NIOSH work practices for manual lifting. If in
doubt, get help.
• Unplug pump when not in use and when changing
accessories.
• Do not use the hose to pull, lift, or carry the
equipment.
• Always work in an area providing good footing
and support.
• Keep work area well-lit, free of clutter, and dry.
Failure to observe these precautions could result in
injury or property damage.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Assembly Instructions
The 940-PS pump is completely assembled and is
shipped to you as a complete pumping unit. The only
assembly necessary is the connections to the ram at
ports provided in the model purchased.
Operating Instructions
This power pump is designed to operate at 10,000 psi
intermittently. For continuous service, as on production
work, the pressure should not exceed 6,000 psi. (This
limitation is for motor protection only.)
Before operating pump, check the following to assure
proper service:
1. Check for proper power connections and for tight-
ness of hose connections before starting pump.
2. Check hydraulic oil with dipstick. Oil should be
within 1/2" of reservoir top.
3. Start motor and allow pump to idle a few minutes.
This will allow the hydraulic oil to work into the
moving parts and give prime to pump.
For operation of control valves, see pages 7 & 8.
Power Connections
The 940-PS is shipped wired for 115 volt AC operation
unless specifically ordered for 230 volt AC operation.
If 230 volt AC operation is desired and your pump has
not been wired at the factory for 230 volt AC the motor
leads must be rewired in accordance with the wiring
diagram shown.
For your protection, ground unit before using.
The electric motor is equipped with an approved
3-conductor cord and 3-blade grounding-type
attachment plug to be used with the proper
grounding-type receptacle, in accordance with
the National Electrical Code. The green-colored
conductor in the cord is the grounding wire, which
is attached to the metal frame of the unit inside the
housing and to the longest blade of the attachment
plug cap. A special grounding adapter is supplied
(except in Canada or for use above 150 volts) to
permit using two-wire receptacles until the correct
receptacle is installed. The green grounding wire
extending from the side of the adapter must be
connected to a permanent ground such as a
properly grounded outlet box, conduit or water
pipe, before plugging in the unit. (If extension
cords are used, they should have sufficient rated
capacity and a properly connected grounding
circuit.)
MotorWiring Diagram
CONNECTIONS FOR CW ROTATION (VIEW MOTOR FROM LEAD END)
LOW VOLTAGE
Purple P1
Brown P2
Black T5
Orange T3
Yellow T4
Red J10
White T2
Purple P1
Brown P2
Black T5
Orange T3
White T2
Red J10
Yellow T4
Insulate This Lead High
Voltage
Line
HIGH VOLTAGE
Low
Voltage
Line
Brown (10)
Violet (9)
Pink (1)
Orange (5)
Black (2)
Red (8)
Blue (4)
Brown (10)
Violet (9)
Pink (1)
Orange (5)
Blue (4)
Red (8)
Black (2)
Franklin GE
Franklin GE

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Pump Specifications
Check to see that vent unit is not clogged before
attempting to operate pump.
Never use synthetic fluids or fluids with poor
lubricating qualities, i.e., brake fluids, etc., as
permanent injury to the pump will result.
Draining Oil Reservoir. Unscrew and remove 3/8 inch
pipe plug (60) from side of pump base. Turn pump on its
side to drain all oil from reservoir. Be sure to replace
plug before refilling reservoir with oil.
Eight quarts are required of which 6-1/4 quarts are
usable. A minimum of 1-3/4 quarts must be at the
bottom of the reservoir at all times during operation.
Be sure that your complete operation does not require
more than the usable amount of oil.
To refill or add oil to the reservoir, proceed as follows:
1. Remove vent unit from top of reservoir (B).
2. Add oil to within 1/2" of top of reservoir when ram is
retracted.
3. Install vent unit (B) securely in place.
Servicing Instructions
Filling Oil Reservoir. The oil reservoir must be kept
filled with a good grade of light hydraulic oil—Greenlee
905 0806.8 hydraulic oil or equal in order or the pump to
operate properly.
Flushing System. As long as these pumps are used as
outlined in the operating instructions, long, trouble-free
performance can be expected. To maintain this perform-
ance, it is absolutely essential that dirt or other foreign
matter be kept out of the system as this is the most
common cause of hydraulic system failure. Therefore,
when opening up the pump for any reason, such as
making pipe connections, adjusting pressure or any
repair, be sure to exercise extreme care in cleanliness
and to use clean tools and cloths. If, at any time, dirt is
suspected to have found its way into the system, the
entire oil system should be flushed as follows:
1. Drain oil from reservoir.
2. Fill reservoir with any recommended flushing oil or
clean kerosene and operate pump. Work the control
handle back and forth several times during flushing
to wash all foreign particles from the control valve
unit.
Note: Do not operate pump for a very long time as
system is not designed to operate with flushing
oil or kerosene.
3. Drain flushing oil or kerosene from reservoir and
refill with new oil.
Motor Maintenance
The 1 hp or 1-1/2 hp motors used on these power
pumps, when in need of repairs, should be repaired by
the manufacturer of the motor or at one of the qualified
GE Service Stations.
TYPE H.P. VOLTS 100 P.S.I. 10,000 P.S.I.
PUMPING CAPACITY
MODEL (CU. IN. PER MIN.) HEIGHT WEIGHT
940-PS
Series
MOTOR
AC 1 115/230 150 30 20
9
/
16
" 10
1
/
2
x 12" 71 lbs. approx.
BASE
DIAMETER

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Minor HydraulicTrouble Chart
The hydraulic unit should be observed constantly for
out-of-the-ordinary performance and unusual noises.
If any of these are present, shut off pump and take
corrective steps immediately to avoid possible expen-
sive repairs later on. In most cases, a minor repair will
solve the problem but it is suggested that, if trouble
continues, the unit should be returned to the factory or
to a qualified service center for the proper repair. Under
no conditions allow unqualified personnel to attempt to
repair the pump, particularly the pump block unit, as
serious, irreparable damage may result.
POSSIBLE REMEDYPROBLEM PROBABLE CAUSE
Improper advance or return. Air in circuit, oil supply low. Add oil. Run unit to work out air.
Dirt system, causing valves to lock Flush out entire oil system and fill with
open. new oil (see page 5).
If trouble is not cleared up by above Drain oil (page 3). Next remove pump-
remedies, trouble may be due to dirty ing unit cover and clean or replace
or plugged-up screen. screens (17).
CAUTION: Do not operate pump
without screens, as particles of dirt
will be sucked into pump and valve
mechanism, seriously damaging
valve seats.
Unable to reach pressure. Same as above. Same as above.
Necessary to add oil often. Oil leaks. Check for broken lines, and loose
fittings or connections.
Noise in hydraulic system. Air in system. Low in oil. Add oil (page 5). Run pump to work
out air.
If the above corrective measures fail to make the pump function, it is recommended that you send the pump back to
the factory or to a qualified service center.

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
The 940-PS Hydraulic Pumps with Control Valves
940-BASIC PS. This pump consists of the basic power
unit without any control valves. It can be adapted very
easily to an SA or TA Model by attaching the type of
valve required.
940-PS. This pump is equipped with a hose connection
unit which permits the connection of 3/8" high pressure
hoses directly to the pump. It can also be adapted very
easily to an SA or TA Model by removing the hose
connection unit and attaching the type of valve required.
See page 8 for Hose Connection Unit 501 6152.0 (C).
940-SA-PS. This pump is equipped with an SA control
valve for operating single-acting rams. It has one 3/8"
NPT outlet port. This model is used when the ram has
spring, manual, or gravity return. The control valve has
two positions, Advance (turn control handle counter-
clockwise to extreme position), or Return (turn control
handle clockwise to extreme position). See page 8 for
SA Valve 501 5644.6 (D).
940-TA-PS Pump. This pump is equipped with a four-
way control valve or operating double-acting rams. This
valve has two 3/8" NPT outlet ports. The lower port is
for the forward (or advance) stroke with a maximum
pressure of 10,000 psi. The upper port is for the return
stroke of the ram at a maximum pressure of 200 psi.
The control handle has three positions: Advance (turn
handle counterclockwise to extreme position), Return
(turn handle clockwise to extreme position). Neutral is in
the middle of these two positions.
This is a positive seat-type valve and therefore position-
ing of the valve in the advance position must be done
firmly to make the seating effective. If stopping the ram
and holding the ram pressure during the advance
operation is required, snap the starting switch on motor
to OFF. The pressure should then be held for a sus-
tained period. See page 8 for TA valve 501 2106.5 (E).
Note: This valve is designed to return the ram piston
only when there is no load on the ram.

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Identification
E
D
C
940-BASIC-PS
940-PS
940-SA-PS
940-TA-PS

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
49
54
42 48
A
45
52
38
27
29
39 41
47
43
46
64
65
62
67
68
58
53
50
69
61
66
63
51
MOMENTARY
ON
SUSTAINED
ON
OFF

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Identification (cont’d)
56
Serial Number
Location 40 44 55
5
8
45
˚
(4)
5
8
7
16
(4)
1
2
10
1
4
9
60
36
37
B
58 57 59
SECTION
CC

Greenlee Textron / Subsidiary of Textron Inc. 11 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
15
35
32
30
9
20
21
10
4
25
2451419
SECTION
BB
617 7 8
3
2
28
23
28
31
11
122316
22
33
1
18
26
34
13

Greenlee Textron / Subsidiary of Textron Inc. 12 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Key Part No. Description Qty
A 501 5693.4 Block Unit, Pump (#1-35)........................................................1
1 501 1732.7 Valve Unit, Lo-Pressure Relief................................................1
2 500 6067.8 Valve Unit, RELIEF .................................................................1
3 501 4854.0 Pump Block.............................................................................1
4 501 4857.5 Plate, Pump Mounting ............................................................1
5 501 4876.1 Shaft, Eccentric.......................................................................1
6 501 4859.1 Block, Intake ...........................................................................1
7 501 4860.5 Plate, Cover ............................................................................1
8 501 4861.3 Plate, Pump ............................................................................1
9 501 1852.8 Spacer, Bearing ......................................................................1
10 501 1855.2 Race, Outer.............................................................................1
11 501 1862.5 Plug, Hi-Pressure Plunger ......................................................1
12 501 1863.3 Plunger, Hi-Pressure ..............................................................1
13 501 1864.1 Bushing, Hi-Pressure Plunger ................................................1
14 501 4862.1 Key, Lo-Pressure Pump..........................................................1
15 501 2621.0 Adapter, Drive Shaft ...............................................................1
16 501 6111.9 Spring, Compression (Discharge) ..........................................1
17 501 6599.2 Screen, Intake.........................................................................1
18 501 4865.6 Spring, Compression (Intake) .................................................1
19 501 4867.2 Gerotor Pump Elements ..................................................... Set
20 905 0989.7 Bearing, .7874 ID x 2.0472 OD x .5906 Thick........................1
21 905 0991.9 Bearing, .9843 ID x 2.0472 OD x .5906 Thick........................1
22 905 0410.0 O-Ring, 3/8 x 1/2 x 1/16..........................................................1
23 905 0436.4 Ball, 9/32 Dia...........................................................................2
24 905 0490.9 Nipple, 3/8 NPT.......................................................................1
25 905 0577.8 Screw, #10-32 NF x 3/4 Socket Head Cap.............................4
26 905 0681.2 Ball, 3/8 Dia.............................................................................1
27 905 0685.5 Washer, #8 Lock .....................................................................4
28 905 0824.6 Plug, 1/16 NPT Pipe ...............................................................2
29 905 0994.3 Screw, #8-32 NC x 1-1/4 Socket Head Cap ...........................4
30 905 0911.0 Roller, .125 x .750.................................................................30
31 905 0912.9 O-Ring, 1/2 x 5/8 x 1/16..........................................................1
32 905 0320.1 Seal, 1-3/8 ID x 2-3/8 OD x 7/16 Thick Oil .............................1
33 905 1097.6 O-Ring, 3 x 3-1/4 x 1/8............................................................1
34 905 1111.5 Screw, 7/16-20 NF x 1/2 Cup Point Socket Set .....................1
35 905 0390.2 Ring, 2-3/8 Dia. Internal Retaining .........................................1
B 501 3076.5 Plug Unit, Vent (#36 & 37) ......................................................1
36 905 0319.8 DRAIN COCK .........................................................................1
37 905 0428.3 Bushing, 3/4 x 1/4 Hex Steel Pipe ..........................................1
38 501 5695.0 Reservoir.................................................................................1
39 501 5697.7 Plate, Motor Mounting.............................................................1
40 501 3918.5 Handle.....................................................................................1
41 501 5646.2 Dipstick Unit ............................................................................1
42 501 4852.4 Key ..........................................................................................1
43 501 5701.9 Gasket, Reservoir ...................................................................1
44 905 0327.9 Screw, #10-32 NF x 5/8 Socket Head Cap.............................2
45 905 0506.9 Washer, 3/8 Lock ....................................................................7
46 905 0530.1 Screw, 3/8-16 NC x 1" Hex Head Cap....................................4
47 905 0713.4 O-Ring, 1/2 x 11/16 x 3/32......................................................1
48 905 0051.2 Screw, 3/8-24 NF x 2" Socket Head Cap ...............................3
49 918 5264.1 Cord, 10 ft. ..............................................................................1
940 Basic PS (501 6548.8) Hydraulic Power Pump — Parts List

Greenlee Textron / Subsidiary of Textron Inc. 13 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940-PS Series Hydraulic Power Pumps
Parts List (cont’d)
Key Part No. Description Qty
940-SA-PS (501 6551.8) Hydraulic Pump (includes #A through 68, & D)
Key Part No. Description
D 501 5644.6 SA Control Valve Unit (see IM 790 for parts)
940-PS (501 6549.6) Hydraulic Pump (includes #A through 68, & C)
Key Part No. Description
C 501 6152.0 Hose Connection Unit
940-TA-PS (501 6552.6) Hydraulic Pump (includes #A through 68, & E)
Key Part No. Description
E 501 2106.5 TA Control Valve Unit (see A-684-IM for parts)
50 918 5183.1 Motor .......................................................................................1
51 918 5223.4 Adapter....................................................................................1
52 905 0522.0 Screw, 5/16-18 NC x 1" Hex Head Cap..................................3
53 918 5127.0 Plug, 1/2" Hole ........................................................................1
54 918 5117.3 Connector, 2-Screw ................................................................2
55 905 0300.7 Washer, #10 x .112 x .068 Lock .............................................2
56 905 0503.4 Plug, 3/8 NPTF Pipe ...............................................................1
57 905 0685.5 Washer, #8 Lock .....................................................................6
58 905 0978.1 Screw, #8-32 NC x 1/4 Round Head Machine......................10
59 501 5699.3 Box, Electrical Outlet ..............................................................1
60 501 5700.0 Cover.......................................................................................1
61 501 6680.8 Switch Unit, Pendant (# 62-67)...............................................1
62 501 7073.2 Cover, Condulet ......................................................................1
63 905 1298.7 Plug .........................................................................................1
64 918 5314.1 Condulet..................................................................................1
65 918 5292.7 Connector ...............................................................................1
66 918 5293.5 Cord, 8 ft. ................................................................................1
67 918 5303.6 Switch......................................................................................1
68 918 5276.5 Relay, Magnetic ......................................................................1
70 905 0806.8 Oil (qt. can) .............................................................................1
71 905 1069.3 Oil (gal. can)............................................................................1

Greenlee Textron / Subsidiary of Textron Inc.
4455 Boeing Drive, Rockford, IL 61109-2988 USA
General Offices: 815/397-7070
Customer Center and Field Service: 800/435-0786
Fax (24 Hour) Customer Center: 800/451-2632 • 815/397-1865
Canada Fax (24 Hour) Customer Center: 800/524-2853 Printed in the U.S.A.