Greenlee 976-22 User manual

HYDRAULIC POWER PUMPS
976-22 (SERIAL CODE YD)
980-22 (SERIAL CODE ABZ)
INSTRUCTION MANUAL
999 9138.1 © 1999 Greenlee Textron IM 1036 REV 14 4/99
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Greenlee Textron / Subsidiary of Textron Inc. 16 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
99
96
97A
98
97
98
97
98
100
G
ELECTRONIC MOTOR CONTROL
GREENLEE
TO MOTOR
GRN-GRD
BLK-L1
WHT-L2
APPLY THERMALLOY
THERMAL COTE 1
THERMAL GREASE TO
BOTTOM OF RELAY
AND SURFACE OF
BASE PRIOR TO
INSTALLATION OF RELAY.
92 95
93
101
91
Motor Control with Cover Removed, Side View
94
UNDER PC BOARD
101
95
93
91
93
92
BLACK WIRE
MOTOR L1
WHITE WIRE
SWITCH CORD POWER CORD
WHITE WIRE L2
WHITE WIRE
MOTOR L2
BLACK WIRE L1
GREEN WIRE
MOTOR GROUND
BLACK WIRE
Motor Control with Cover Removed
Service
Motor Control Unit

Greenlee Textron / Subsidiary of Textron Inc. 17 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
R1 2
43
+-
3-32 VDC
REMOTE SWITCH
CORD W/PLUG
240 VAC
45 AMP
BLACK
WHITE
BLACK
BLACK
8
7
6
5
4
1
100 V
1 AMP
BLACK
GREEN
16 VDC
47yF +
WHITE
POWER CORD
WHITE
220 V
@ 1.12 VA
GREEN
CONTROL UNIT
(COMMON WIRING)
3
2
8 V
Motor Control, Schematic Diagram
85
90
108
86 87 89
88
Pendant Switch
BLACK
WIRING DIAGRAM
SWITCH MOUNTED TO
GUARD WITH TWO #10
SCREWS (SUPPLIED
WITH GUARD)
WHITE
CND
NC
111
110
109
108
Foot Switch
Service (cont’d)

Greenlee Textron / Subsidiary of Textron Inc. 18 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
Hydraulic Schematic
1
Intake strainer, #50 mesh brass screen
2Low-pressure pump — 3.4 liters/min. (208 in3/min)
at 3000 rpm (100%)
3Low-pressure relief valve — 19 Bar (275 psi)
located in pilot-operated valve
7
Piston
4Low-pressure bypass check valve
5
High-pressure pump
976-22: .25 liters/min. (15 in
3
/min) at 2850 rpm (100%)
980-22: .73 liters/min. (45 in3/min)
6High-pressure relief valve
717/690 Bar (10,400/10,000 psi)
7Pilot-operated directional control valve
3 way, 2 position
8Manually operated check valve
9
Female coupler half
6
8
7
3
4
9
5
2
1
Service (cont’d)
Driv-Lok Pin
Seal the Driv-Lok pin (73) to the pump block (84) with
a 1.5 mm (1/16") bead of an RTV-type silicone-based
sealant, such as Dow Corning 732™ Multipurpose
Sealant or equivalent.
Sealing Instructions for Assembly
Motor
If the motor has been disassembled, seal with a 3 mm
(1/8") bead of a silicone-based gasket/flange sealant,
such as Loctite®587 Ultra Blue®, as follows:
(A) To the mounting surface around the threads
(four locations)
(B) To the chamfer (four locations)
(C) Around the innermost machined circumference
of the mounting surface
Apply a 1.5 mm (1/16") bead of an RTV-type silicone-
based sealant, such as Dow Corning 732™ Multipurpose
Sealant, as follows:
(D) Around the motor bearing screws (two locations)
Assemble immediately.
73
84
AB
D
C

Greenlee Textron / Subsidiary of Textron Inc. 19 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
The following section and Figures describe pertinent
details for refinishing ball seats and component
re-assembly and adjustments.
Motor Face Seal
When reassembling the motor, refer to Figure A1 for the
face seal seating dimension. Also, refer to this figure for
setting the vertical position of counterweight (32).
Manual Release / Automatic
Release Valve Handle Setting
Refer to Figures A2 and A3. Thread in the shaft (62)
until it just touches the check ball (55) (in its spring-
loaded closed position). Slide collar (104) on the shaft.
Position the handle (61) at the location “Position 1,”
(Figure A3), with the other surface of the handle flush
with the end of the shaft. Lock in place. Rotate the
handle to “Position 2,” (Figure A3). Slide the collar
toward the valve body until it contacts the 15.9 mm
(5/8") diameter portion of the control shaft. Rotate the
lock collar clockwise until it touches the stop pin, and
lock in place.
When locking control handle and lock collar in
place, torque set screws to 2.8 - 3.4 Newton-meters
(25-30 inch-pounds).
22 21
MOTOR SHAFT
MOTOR FACE
4.6 mm (.180 inch)
4.1 mm (.160 inch)
32
8
6mm (.234 inch)
Figure A1
54 55 60
62
104
61
Figure A2
0.312" (7.938 mm) ø BALL SEAT
STOP
PIN
8
45°
STOP
CLOSED
STOP
OPEN
BALL OPEN
112.5°(.99 mm [.039"])
POSITION 2
SET POSITION #1
22.5°(REF.)
135°
Figure A3
8
Service (cont’d)

Greenlee Textron / Subsidiary of Textron Inc. 20 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
Low Pressure Relief Setting
Refer to Figure A4. Lightly bottom the stem (44) on the
ball (46). Then, back out the stem 3-1/2 turns. Tighten
nut (43). The resulting pressure setting should be
approximately 19.3 Bar (280 psi).
Service (cont’d)
44
3
Figure A4 7
42
47
43
45
46
49
48
Low-Pressure Bypass Check Pressure Adjustment
When properly set to the dimension shown in Figure A5,
the high pressure stage operation of the pump will be
delayed approximately one (1) second after the motor
starts. This delay is created by the closing time of the
pilot-operated valve.
Note: This dimension must be increased if ball
seat depth is increased by more than
.4 mm (1/64 inch).
Increasing the bypass pressure (CW rotation of adjusting
screw—increase of set dimension) will shorten delay. If
delay becomes too short, the motor will not restart when
high pressure is held in the line. The motor should restart
with a maximum required off time of 1/2 to 1 second.
Decreasing the bypass pressure (CCW rotation of
adjusting screw) will increase delay. The pilot-operated
valve will not close if pressure is set too low.
Changes in oil temperature (viscosity) will affect the
amount of delay. The pumping delay will increase with
rising oil temperature (thinner oil).
COVERPLATE
36.17 mm (1.424") 8 mm (5/16") Ø BALL
(used to make measurement)
37.29 mm (1.468")
69
70
71
4
Figure A5
78
Figure A6
High-Pressure Inlet Check Ball Travel
The amount of allowable ball travel is critical to the
optimum high pressure output (flow rate). Refer to
Figure A5-1. Carefully and accurately measure (depth
“mike”) the “A” dimension (top of pump block to seated
ball) and “B” dimension (top of pump block to head of
plug—at center). Carefully and accurately set the “C”
dimension (overall length of assembled plug and pin)
of a new plug and pin equal to “A” minus “B” minus
.305 ±.050 mm (.012 ±.002 inches).
TOP OF
PUMP BLOCK
A
5
Figure A3-1
C
B
TRAVEL
.305 mm
(.012 inch)
42 79
105
Low Pressure Pump Drive Pin
Assemble with cone point end in half-round keyway.

Greenlee Textron / Subsidiary of Textron Inc. 21 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
Service (cont’d)
Ball Seat Refinishing
Refer to Figures B2, B3, and B4 for the proper drill size
to refinish the conical seat and finish ream size. These
operations must be performed with the pump or valve
block properly held and using a drill press. Only a very
small amount of material should be removed.
4
Figure B3
COVERPLATE
5
8.43 mm (“Q” 0.332") Ø DRILL
4.76 mm (0.187") Ø BALL SEAT
(INTAKE CHECK)
3.45 mm (#29 0.136") Ø REAM
4.76 mm (0.187") Ø REAM
7.14 mm (0.281") Ø BALL SEAT
(DISCHARGE CHECK)
9.35 mm (“U” 0.368") Ø DRILL
9.35 mm (“U” 0.368") Ø DRILL
7.14 mm (0.281") Ø BALL SEAT
(BYPASS CHECK)
4.76 mm (0.187") Ø REAM
3
Figure B2 7
3.175 mm (.125") Ø REAM
4.76 mm (.187") Ø BALL SEAT
(P.O. VALVE)
7.14 mm (.281") Ø DRILL
11.51 mm (.453") Ø DRILL
6.35 mm (.250") Ø BALL SEAT
(LO-P RELIEF VALVE)
4.76 mm (.187") Ø REAM
8
Figure B4
9.53 mm (0.375") Ø DRILL
7.14 mm (0.281") Ø REAM
7.94 mm (0.312") Ø BALL SEAT
(LINE CHECK VALVE)

Greenlee Textron / Subsidiary of Textron Inc. 22 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
ExplodedView
19
7
7
6
12
222
1
13
23
21
10
4
16
26
31
27
99
26
27
31
8
100
34
14
9
2 28
2
3
15
2
1
13
24
25
24
25
12
35
17
18
33
32 11
28
11
1
1
1
1
Figs A1 & A5
Fig. A2
Fig A4
Serial
No.

Greenlee Textron / Subsidiary of Textron Inc. 23 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
78
7
7
50
49
48
46
45
44
47
7
43
42
71
70
69
107
68
73
72
71
70
69
105
79 106
42
58 56 57
104
61
60
112
55
52
64 63
59
66
65
34
32
36
33
41
38
39
40
77
103
41 980-22
980-22
976-22
76
75
84
80
81
102
82
83
7
37
113
62
54
53
9
2
2
5
63
4
4
2
74
976 Only
See Driv-Lok Pin under
Sealing Instructions
for Assembly in the
Service Section.
ExplodedView—Pump Block
11.13 - 1.35 N•m 10 - 12 inch-pounds
22.8 - 3.4 N•m 25 - 30 inch-pounds
3110 N•m 80 foot-pounds
427 N•m 20 foot-pounds
534 N•m 25 foot-pounds
668 N•m 50 foot-pounds
503 4369.6
Hydraulic Repair Kit
503 5464.7
Release Knob Retrofit Kit
TorqueTable

Greenlee Textron / Subsidiary of Textron Inc. 24 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
Parts List
KEY PART NO. DESCRIPTION QTY.
1 503 3518.9 Carrying Handle...................................................2
2 905 3709.2 1/4–20 x 1-1/4" Hex Head Screw ........................8
3 503 4432.3 Decal, Identification 976-22.................................1
503 6307.7 Decal, Identification and Specification 980-22 ....1
4 918 6353.8 Motor, 220 VAC, 1/2 HP (976-22) .......................1
918 6444.5 Motor, 220 VAC, 1-1/2 HP (980-22) ....................1
6 503 2661.9 Fill-Vent Plug .......................................................1
7 905 0520.4 1/4–20 x 3/4" Hex Head Screw ..........................14
8 503 4396.3 Motor Control Unit, (includes 91-101) .................1
9 905 0807.6 Coupling...............................................................1
10 503 3488.3 Shroud .................................................................1
11 503 3490.5 Reservoir, 976-22 ................................................1
503 3555.5 Reservoir, 980-22 ................................................1
12 503 3535.9 Short Retaining Strap ..........................................2
13 503 3536.7 Long Retaining Strap...........................................2
14 503 3537.5 Release Valve Unit, (includes 52-66) ..................1
15 503 4398.0 I.D. Decal, Specifications and Warning 976-22...1
503 5491.4 I.D. Decal, Warning 980-22 .................................1
16 501 5832.5 Arrow Decal .........................................................1
17 Eccentric Unit (see Exploded View—Pump Block) .. 1
18 Pump Block Unit
(see Exploded View—Pump Block) ............................ 1
19 905 0530.1 Hex Hd. Cap Screw, 3/8–16 x 1.00"....................3
*21 905 3682.7 Seal......................................................................1
22 503 3517.0 Cover Plate ..........................................................1
*23 503 2627.9 Cover Plate Gasket .............................................1
24 905 3829.3 Rubber Foot.........................................................4
25 905 1185.9 Screw, 1/4–20 x 1/2"............................................4
26 905 1460.2 Self-Tapping Screw 10 x 3/8" ..............................2
27 905 3468.9 #10 Flat Washer ..................................................2
28 905 2339.3 1/4" Flat Washer ..................................................4
31 503 9896.2 Mounting Strap ....................................................1
32 503 3527.8 Counterweight......................................................1
33 905 1269.3 Set Screw, 1/4–20 x 1/4" .....................................1
34 501 4557.6 Motor Shaft Key, 3/16" x 1-3/8" ...........................1
35 905 0533.6 Hex Hd. Cap Screw 3/8–16 x 1.50".....................1
36 905 3707.6 Retaining Ring .....................................................1
37 905 3758.0 Ball Bearing #1206 ..............................................1
38 503 3526.0 Eccentric Shaft.....................................................1
39 905 0699.5 Rollpin, 3/16" x 1" ................................................1
40 905 0791.6 Set Screw, 10–32 x 1/4" ......................................1
41 905 3704.1 Ball Bearing, #3206 .............................................1

Greenlee Textron / Subsidiary of Textron Inc. 25 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
976-22, 980-22 Hydraulic Power Pump
Parts List (cont’d)
KEY PART NO. DESCRIPTION QTY.
* 42 905 0678.2 Ball, 3/16".............................................................2
43 905 0016.4 Jam Nut, 1/2–20 ..................................................1
44 503 3520.0 Stem.....................................................................1
45 502 2534.5 Spring ..................................................................1
*46 905 0679.0 Ball, 1/4"...............................................................1
47 905 3701.7 Spring ..................................................................1
48 503 3519.7 Auto Valve Piston ................................................1
*49 905 0340.6 O-Ring, 1-5/8" x 2" x 3/16" ..................................1
50 503 3521.9 Pump Block Cover ...............................................1
*52 905 3503.0 Retaining Ring .....................................................1
53 905 3468.9 Plain Flat Type “A” Washer .................................1
54 905 3510.3 Compression Spring ............................................1
*55 905 0680.4 Ball, 5/16".............................................................1
56 503 2622.8 Coupling...............................................................1
*57 905 1290.1 Back-up Ring, 3/8" x 1/2" x 1/16" ........................2
*58 905 0168.3 O-Ring, 3/8" x 1/2" x 1/16"...................................2
*59 503 2626.0 Gasket .................................................................1
+60 905 1269.3 Set Screw, 1/4–20 x .38" .....................................2
+61 503 4796.9 Release Valve Knob ............................................1
62 503 3541.3 Control Shaft........................................................1
*63 905 3827.7 Back-up Ring, 1/2" x 5/8" x 1/16" ........................1
*64 905 0912.9 O-Ring, 1/2" x 5/8" x 1/16"...................................1
65 905 3496.4 Cap Screw, 5/16–18 x 2.50"................................2
66 503 2623.6 Release Valve Body ............................................1
*68 905 3698.3 O-Ring Plug (includes 107) .................................1
69 905 3712.2 Jam Screw, 7/16".................................................2
70 905 3702.5 Spring ..................................................................2
*71 905 0436.4 Ball, 9/32".............................................................2
72 500 6067.8 High Pressure Relief Valve..................................1
73 905 3706.8 Pin, Type “D” Driv-Lok 1/4" x 1/2" .......................1
74 503 4310.6 Insert, Cavity, (976-22 Only) ...............................1
75 503 3531.6 High Pressure Bushing, 976-22 ..........................1
503 3530.8 High Pressure Bushing, 980-22 ..........................1
76 503 3532.4 High Pressure Piston, 976-22 .............................1
503 3528.6 High Pressure Piston, 980-22 .............................1
77 503 3525.1 Drive Shaft ...........................................................1
78 503 2934.0 Drive Pin ..............................................................1
*79 905 3699.1 O-Ring Plug, (includes 106) ................................1
80 905 3517.0 Gerotor.................................................................1
81 503 4197.9 Lower Gerotor Plate Unit (includes 102) .............1
82 503 3524.3 Filter.....................................................................1
*83 905 3766.1 O-Ring, 2-3/8" x 2-5/8" x 1/8" ..............................1

Parts List (cont’d)
KEY PART NO. DESCRIPTION QTY.
84 503 3533.2 Pump Block..........................................................1
85 503 2370.9 Faceplate Decal...................................................1
86 918 6265.5 Switch ..................................................................1
87 503 1902.7 Handle, Right Half ...............................................1
88 905 3441.7 Self-Tapping Screw, 6–20 x 5/8" .........................3
89 503 1901.9 Handle, Left Half..................................................1
90 503 2362.8 Cord .....................................................................1
91 503 3491.3 Motor Control Base..............................................1
92 918 6292.2 Relay, 240 VAC/8 VDC — 45A ...........................1
93 905 3840.4 Self-Tapping Screw, 6–32 x 5/16".......................6
94 905 3695.9 Pan Head Type C Screw, 6–32 x 1/4".................2
95 503 4399.8 Transformer Unit..................................................1
96 503 3492.1 Motor Control Cover ............................................1
97 905 3580.4 Pan Head Mach. Screw, 6–32 x 5/8"...................2
97A 905 4879.5 Pan Head Mach. Screw, 6–32 x 3/8"...................1
98 905 0632.4 Hex Nut, 6–32......................................................3
99 918 6845.9 96" Long Cord......................................................1
100 918 6052.0 Female Twist Lock Cord Connector ....................1
101 905 3831.5 Nylon Spacer, .150" ID x 5/16" OD x .050" .........4
102 905 3839.0 Bearings, Bronze .................................................1
103 905 3320.8 Bearings, Bronze .................................................1
+104 503 4886.8 Shaft Stop Collar .................................................1
*105 905 3816.1 Pin, 1/8" x 1/4" Driv-Lok.......................................1
*106 905 3878.1 O-Ring .................................................................1
*107 905 3880.3 O-Ring .................................................................1
108 918 6051.2 Plug, Twist Lock Male..........................................1
109 918 6312.0 Cord, Foot Switch ................................................1
110 918 6355.4 Switch, Foot .........................................................1
111 918 6356.2 Guard, Foot Switch..............................................1
+112 905 0078.4 Roll Pin, 3/16" x 3/4"............................................1
113 905 0501.8 Plug Pipe 1/8" Skt. Hd. ........................................1
* Parts included in Repair Kit No. 503 4369.6
+ Parts included in Release Knob Retrofit Kit 503 5464.7
Printed in the U.S.A.
Greenlee Textron / Subsidiary of Textron Inc.
4455 Boeing Drive, Rockford, IL 61109-2988 USA
Customer Service (International): 815/397-7070 • Fax: [phone]
Customer Service (North America): 800/435-0786 • Fax: [phone]
Canada Fax: [phone]