Greenlee 940 User manual

OPERATION, SERVICE AND PARTS
INSTRUCTION MANUAL
999 5541.5 © 1997 Greenlee Textron IM 841 REV 3 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.
940 & 960-PO-PS
M3 Series
HYDRAULIC POWER PUMPS
For all pumps with Serial No. Code LE & MT

Greenlee Textron / Subsidiary of Textron 2
Hydraulic Power Pumps
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Table of Contents
Safety Information.................................................................................2-3
Introduction ..............................................................................................4
Assembly .................................................................................................4
Power Connection ...................................................................................4
Operating Instructions..............................................................................5
Servicing ..................................................................................................5
Pump Specifications ................................................................................6
Motor Maintenance ..................................................................................6
Minor Hydraulic Problems........................................................................6
Troubleshooting .......................................................................................6
Identification Views ...............................................................................7-8
Parts List .............................................................................................9-10
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.

34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Power Pumps
Greenlee Textron / Subsidiary of Textron
SAVETHESE INSTRUCTIONS
Additional copies of this manual are available upon request at no charge.
IMPORTANT SAFETY INSTRUCTIONS
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.
• Inspect 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.
Electric shock hazard:
• Do not expose power tools to rain.
• Do not immerse the pendant
switch in water or other liquid.
• 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.
• 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 4
Hydraulic Power Pumps
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Introduction
These are high-pressure hydraulic power pumps which
are simple to operate, lightweight, durable and portable.
These power pumps have a built-in, high volume / low
pressure pumping feature which gives fast approach
ram action and automatic change-over to low volume /
high pressure when pressure exceeds 200 psi. The
pumping unit consists of a one-piston radial-type
capable of developing 10,000 psi. A safety valve set at
10,000 psi protects the unit against excessive pres-
sures. It is also equipped with an automatic pressure-
operated valve which provides high pressure advance
of the ram while the motor is running. Pressure is
automatically released when motor stops.
The pump is controlled by a two-position pendant switch
which runs the pump motor when held in the down
position. When released, the pump motor shuts off.
Assembly
These pumps are completely assembled and are
shipped to you as a complete pumping unit. The only
assembly necessary is the connection of the ram to the
pump and the power cord to the proper electrical outlet.
Power Connection
The pumps are designed and shipped wired for 115
Volt, AC operation. They cannot be wired for 230 Volts
without changing to a 230 Volt relay. If 230 Volts is
required and has not been wired at the factory, the
motor leads must be rewired in accordance with the
wiring diagram shown.
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
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.)

54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Power Pumps
Greenlee Textron / Subsidiary of Textron
Operating Instructions
These power pumps are designed to operate at 10,000
psi intermittently. For continuous service, as on produc-
tion 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 moving
parts and give prime to pump.
Servicing
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 for the pump to operate properly.
Draining Oil Reservoir
Unscrew and remove 3/4 inch pipe plug (74) from side
of pump base. Turn pump on its side to drain all oil from
reservoir. Be sure to replace plug before refilling reser-
voir with oil.
Flushing System
As long as the pump is used as outlined in the operating
instructions, long, trouble-free performance can be
expected. To maintain this performance, 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, 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.
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.
Never use synthetic fluids or fluids with poor lubri-
cating qualities (i.e., brake fluids, etc.) as permanent
injury to the pump will result.
Eight quarts are required, of which 6-1/2 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.
Check to see that vent unit is not clogged before
attempting to operate pump.

Greenlee Textron / Subsidiary of Textron 6
Hydraulic Power Pumps
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Troubleshooting
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
Improper advance or return. Air in circuit, oil supply low. Add oil, run unit to work out air.
Dirt in system, causing valves to Flush out entire oil system and
lock open. fill with new oil (see page 5).
If trouble is not cleared up by above Drain oil (see page 5). Next
remedies, trouble may be due to dirty remove pumping unit cover
or plugged-up screen. and clean or replace screen (26).
CAUTION: Do not operate
pump without screens, as particles
of dirt will be sucked into pump and
valve mechanisms, 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, 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 properly, it is recommended that you send the pump back
to the factory or to an authorized Greenlee service center. Under no conditions, allow unqualified personnel to attempt to
repair the pump (particularly the pump block unit or control valve unit), as serious irreparable damage may result.
Pump Specifications
Model Motor 115V Pumping Capacity Dimensions Approx.
No. 60 Hz 1 ph In. Cu./Min. In Inches Weight (lbs.)
100 psi 10,000 psi Height Base
940-M3-PO-PS 1 hp 150 30 18-1/4 12 x 10-1/2 82
960-M3-PO-PS 1-1/2 hp 300 60 20 12 x 10-1/2 92
Correcting Minor Hydraulic Problems
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. See Troubleshooting charts for
some of the most common minor troubles and their
solutions.
Motor Maintenance
If the pump motor is in need of repair, it should be done
by the manufacturer of the motor or a qualified service
center.

74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Power Pumps
Greenlee Textron / Subsidiary of Textron
74
SERIAL NUMBER
LOCATION 69
62
51
B
50
84
82
60
63
64
65
61
77
75
81
66
71
80
67
75
ALLEN
WRENCH
52
72
68
73 78
76
70
A
C
Note: Remove set screw
before removing
motor.

Greenlee Textron / Subsidiary of Textron 8
Hydraulic Power Pumps
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
22 41 27
85
34
34
30
1
81
75
76
72
2
31
22
12
35
17
18
25
13
9
15
16
10
14
19
29
38
34
4
24
40
32
27
6
37
23
11 20
7
22 43
26
8
33
39
R
O
T
A
T
I

94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Power Pumps
Greenlee Textron / Subsidiary of Textron
Hydraulic Power Pumps — Parts List
940-M3-PO-PS (501 8608.6)
960-M3-PO-PS (501 0860.6)
Key Part No. Description Qty
A 501 8621.3 Block Unit, PO Pump (1-43) ..............................................................1
1 500 6067.8. Valve Unit, Relief...............................................................................1
2 501 7766.4 Valve Unit, Relief...............................................................................1
3 501 7345.6 Plate, Pump Mounting .......................................................................1
4 501 8871.2 Spacer, Bearing.................................................................................1
5 501 1855.2 Race, Outer .......................................................................................1
6 501 1862.5 Plug, Plunger.....................................................................................1
7 501 9060.1 Plunger, High Pressure .....................................................................1
8 502 0424.6 Block, Intake ......................................................................................1
9 501 4861.3 Plate, Pump .......................................................................................1
10 501 4862.1 Key.....................................................................................................1
11 501 4876.1 Shaft, Eccentric .................................................................................1
12 501 5958.5 Piston, Valve......................................................................................1
13 501 7130.5 Plate, Top ..........................................................................................1
14 501 7131.3 Plate, Bottom .....................................................................................1
15 501 7135.6 Vane ..................................................................................................4
16 501 7136.4 Rotor..................................................................................................1
17 501 7347.2 Stop, Valve Piston .............................................................................1
18 501 7348.0 Plunger, Release...............................................................................1
19 501 7467.3 Dowel, Hollow....................................................................................1
20 501 8238.2 Adapter, Drive Shaft ..........................................................................1
21 501 8622.1 Block, PO Pump ................................................................................1
22 500 6111.9 Spring, Compression.........................................................................5
23 501 9059.8 Bushing, Plunger ...............................................................................1
24 501 4865.6 Spring, Compression.........................................................................1
25 501 4893.1 Spring, Compression.........................................................................1
26 502 1175.7 Screen, Intake ...................................................................................1
27 905 0436.4 Ball, 9/32 Chrome Steel ....................................................................2
29 905 0501.8 Plug, 1/8 NPT Socket Head Pipe ......................................................1
30 905 0577.8 Screw, #10-32 NF x 3/4 Socket Head Cap .......................................6
31 905 0680.4 Ball, 5/16 Chrome Steel ....................................................................1
32 905 0681.2 Ball, 3/8 Chrome Steel ......................................................................1
33 905 1526.9 Washer, #8 Hi-Collar Lock ................................................................4
34 905 0824.6 Plug, 1/16 NPT Socket Head Pipe ....................................................7
35 905 0839.4 O-Ring, 1-3/8 x 1-1/2 x 1/16..............................................................2
36 502 2611.8 Roller, 1/8 x 3/4 ...............................................................................30
37 905 1524.2 O-Ring, 1/2 x 5/8 x 1/16 ....................................................................1
38 905 0989.7 Bearing, .7874 ID x 2.0472 OD x .5906 Thick ..................................1
39 905 0994.3 Screw, #8-32 NC x 1-1/4 Socket Head Cap......................................4
40 905 1111.5 Screw, 7/16-20 NF x 1/2 Cup Point Socket Set ................................1
41 905 1215.4 O-Ring, 7/16 x 9/16 x 1/16 ................................................................1
42 905 1337.1 Screw, 5/16-24 NF x 5/32 Socket Jam..............................................2
43 905 1473.4 Bearing, .9843 ID x 2.0472 OD x .5906 Thick Ball ...........................1
C 502 0721.0 Cord Unit, PS Power (52 & 60-65) ....................................................1
52 503 2363.6 Switch, Pendant.................................................................................1
60 501 8443.1 Enclosure, Relay ...............................................................................1
61 918 5117.3 Connector ..........................................................................................2
62 918 5264.1 Cord, 10-foot......................................................................................1
63 918 5364.8 Relay, 115 Volt ..................................................................................1
64 905 1523.4 Screw, #6 x 3/8 Slotted Sheet Metal .................................................2
65 905 1252.9 Screw, #6-32 NC x 1/4 Round Head Thread Cutting........................2
66 501 5646.2 Dipstick Unit.......................................................................................1

Parts - Hydraulic Power Pumps (cont’d)
940-M3-PO-PS (501 8608.6)
960-M3-PO-PS (501 0860.6)
67 501 6152.0 Connection Unit, Hose ......................................................................1
68 501 5695.0 Reservoir ...........................................................................................1
69 501 2663.6 Handle, Lifting....................................................................................2
70 501 8292.7 Plate, Motor Mounting .......................................................................1
71 501 4852.4 Key.....................................................................................................1
72 501 5701.9 Gasket, Reservoir..............................................................................1
73 905 0320.1 Seal, 1-3/8 ID x 2-3/8 OD Oil ............................................................1
74 905 0734.7 Plug, 3/4 NPTF Socket Head Pipe....................................................1
75 905 0506.9 Washer, 3/8 x .136 x .070 Lock.........................................................8
76 905 0522.0 Screw, 5/16-18 NC x 1" Hex Head Cap ............................................3
77 905 0532.8 Screw, 3/8-16 NC x 1-1/4" Hex Head Cap........................................4
78 905 0713.4 O-Ring, 1/2 x 11/16 x 3/32 ................................................................1
80 905 1269.3 Screw, 1/4-20 NC x 1/4 Cup Point Socket Head Set........................1
81 905 1474.2 Screw, 3/8-24 NF x 2-1/2 Socket Head Cap.....................................4
82 918 5183.1 Motor, 1 HP, 1725 RPM (904-M3-PO-PS) ........................................1
84 918 5300.1 Motor, 1-1/2 HP, 3450 RPM (960-M3-PO-PS)..................................1
85 502 0858.6 Block, PO Pump ................................................................................1
86 501 7864.4 Piston, Valve......................................................................................1
87 501 6608.5 Plunger, Release...............................................................................2
Key Control No. Description Qty
Printed in U.S.A.
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
International Customer Service: 815/397-7070
Fax (24 Hour) Customer Center: 800/451-2632 • 815/397-1865
Canada Fax (24 Hour) Customer Center: 800/524-2853
International Fax (24 Hour) Customer Service: 815/397-1391
GREENLEE