Greenlee 940m3 SERIES Guide

OPERATION, SERVICE AND PARTS
INSTRUCTION MANUAL
999 6463.5 © 1997 Greenlee Textron IM 791 REV 1 7/97
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 SERIES
HYDRAULIC POWER PUMP

Greenlee Textron / Subsidiary of Textron 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940 Series Hydraulic Power Pump
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.
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
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.
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
Greenlee Textron / Subsidiary of Textron
940 Series Hydraulic Power Pump
SAVETHESE INSTRUCTIONS
Additional copies of this manual are available upon request at no charge.
IMPORTANT SAFETY INSTRUCTIONS
• 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.
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.
• 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 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940 Series Hydraulic Power Pump
Introduction
The 940 is a high-pressure hydraulic power pump
which is simple to operate, lightweight, constructed with
extreme durability and is portable. The 940 features a
supercharger which provides low pressure / high volume
delivery for rapid advance of the ram to the work and
automatic change-over to low volume / hi-pressure
delivery when ram pressure exceeds 200 psi. The pump
is a one-piston radial-type capable of developing 10,000
psi. The pump unit contains two valves; one is set at
10,000 psi to control the low volume / hi-pressure
delivery, and the other is set at 200 psi to control the
high volume / low pressure delivery.
Assembly
The 940 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 pro-
vided in the model purchased.
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.)
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
Power Connection
The 940 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 the 230 volt AC, the
motor leads must be rewired in accordance with the
wiring diagram shown.

54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Greenlee Textron / Subsidiary of Textron
940 Series Hydraulic Power Pump
Operating Instructions
This pump is designed to operate at 10,000 psi inter-
mittently. 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 moving
parts and give prime to pump.
For operation of control valves see page 8.
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 (56) 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, such as making pipe connec-
tions, 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.
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 securely in place.
Check to see that vent unit is not clogged before
attempting to operate pump.
Never use synthetic fluids or fluids with poor lubri-
cating qualities (i.e., brake fluids, etc.), as permanent
injury to the pump will result.

Greenlee Textron / Subsidiary of Textron 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940 Series Hydraulic Power Pump
Pump Specifications
Model Motor Pumping Capacity Height Base Dia. Weight
(Cu. In./Min)
Type Horse Volts 100 10,000
Power psi psi
AC 1 hp 115/230 150 30
940 20-9/16" 12" x 71 lbs.
10-1/2" approx.
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.
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.

74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Greenlee Textron / Subsidiary of Textron
940 Series Hydraulic Power Pump
Troubleshooting
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 (17).
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.
PROBLEM PROBALE CAUSE POSSIBLE REMEDY

Greenlee Textron / Subsidiary of Textron 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940 Series Hydraulic Power Pump
The 940 Hydraulic Pump with Control Valves
940-TA Pump
This pump is equipped with a four-way control valve,
panel-mounted, for 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 9 for TA valve 501 2106.5,
Key E.)
Note: This valve is designed to return the ram piston
only when there is no load on the ram. If the
operation requires the return of the piston while
sustaining a load the TB control valve should be
used.
940-SA Pump
This pump is equipped with a 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. It also has a holding feature, whereby the
ram is held stationary under pressure (with motor
running) when the control handle is in Neutral position.
The control valve has three positions. Advance (turn
control handle counterclockwise to extreme position),
Neutral, or Hold, (turn control handle clockwise to
middle position), and Return (turn control handle
clockwise to extreme position). When the control handle
is in Neutral position the pump is unloaded but the ram
pressure is held. (See page 7 for SA Valve 501 5644.6,
Key D.)
940-TB Pump
This pump is equipped with a 1704 spool valve with
sub-plate panel-mounted, and is used for operating
double-acting ram.
The spool is spring-returned to Neutral from Advance
and Return positions. The sub-plate has two 3/8" NPT
ports, marked Cyl. 1 and Cyl. 2. Cylinder 1 port is the
high pressure port and should be connected to the
advance port in the ram. Cylinder 2 is the return port,
750 psi maximum, and should be connection to the
return port in the ram.
To advance the ram, push the control lever forward
(toward the valve body) to its extreme position. To
return the ram, pull the control lever away from the
valve body. Because of the balanced design of this
valve it will be noted that it operates as easily under full
load as at no load. At no time is great effort required to
move the lever.
The above 1704 spool valve and 501 2256.8 sub-plate
with relief valve are standard equipment on the 940-TB
pump. On special order the pump can be supplied
with a 501 2441.2 sub-plate without relief valve which
will deliver 10,000 psi through both cylinder ports. Also
available on special order is the 1717 4-way control
valve in which the spool is detent held in position.
(See page 7 for Valve 1704 [F] and Sub-Plate
501 2256.8[G].)

94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Greenlee Textron / Subsidiary of Textron
940 Series Hydraulic Power Pump
940-TB
940-TA
940-SA
940
940-BASIC
C
D
E
G
F
940 Series Pumps

Greenlee Textron / Subsidiary of Textron 10 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940 Series Hydraulic Power Pump
49
54
42
52
41
47
A
38
43
39
46
53
50
2729
48
45
51
940 Series Pumps (cont’d)

11 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Greenlee Textron / Subsidiary of Textron
940 Series Hydraulic Power Pump
36
B
5.37
9.50
10.75
SECTION CC
37
56 40 44 55
940 Series Pumps

Greenlee Textron / Subsidiary of Textron 12 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
940 Series Hydraulic Power Pump
2
28
19 14 5 24 6 17 7 8
31
13
34
26
18
23
28
1
33
22
16
23
12
11
30
9
20
3
4
25
15
10
35
32
21
SECTION BB
940 Series Pumps (cont’d)

13 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Greenlee Textron / Subsidiary of Textron
940 Series Hydraulic Power Pump
940 Series Hydraulic Power Pump — Parts List
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
16 500 6111.9 Spring, Compression (discharge) ................................................................. 1
17 501 3179.6 Screen, Intake ...............................................................................................1
18 501 4865.6 Spring, Compression (intake) .......................................................................1
19 501 4867.2 Gerotor Pump Elements............................................................................ Set
20 501 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 0992.7 Nipple, 3/8 NPT x 1-1/2 Black Pipe .............................................................. 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
30 502 2611.8 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 .......................................................................................................... 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
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 5284.6 Switch, Toggle...............................................................................................1
54 918 5117.3 Connector, Two Screw.................................................................................. 1
55 905 0300.7 Washer, #10 x .112 x .068 Lock ................................................................... 2
56 905 0503.4 Plug, 3/8 NPTF Pipe .....................................................................................1
65 905 0806.8 Oil ......................................................................................................1 qt. can
66 905 1059.3 Oil .................................................................................................... 1 gal. can
When ordering parts,
give serial no. of pump

Parts - Hydraulic Power Pumps (cont’d)
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
940
501 5679.9 Hydraulic Pump (includes #A through 56 plus C)
Key Control No. Description
C 501 6152.0 Hose Connection Unit
940-SA
501 5680.2 Hydraulic Pump (includes #A through 56 plus D)
Key Control No. Description
D 501 5644.6 SA Control Valve Unit
(see IM 790 for parts)
940-TA
501 5681.0 Hydraulic Pump (includes #A through 56 plus E)
Key Control No. Description
E 501 2106.5 TA Control Valve Unit
(see A-684-IM for parts
940-TB
501 5682.9 Hydraulic Pump (includes #A through 56 plus F & G)
Key Control No. Description
F 500 2781.6 4-way Spring-Centered Spool Valve
(1704) (see IM 686-B for parts)
G 501 2256.8 Sub-Plate Unit
(see IM 686-B for parts)