Textron Greenlee 763 User manual

99928752 © 2006 Greenlee Textron Inc. IM 1360 REV 2 5/06
763 & 764M4
Ratchet Cable Cutters
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
INSTRUCTION MANUAL
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Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
Description ..................................................................... 2
Purpose of this Manual .................................................. 2
Important Safety Instructions ......................................3-4
Identification ................................................................... 5
Specifications ................................................................. 5
Operation ....................................................................... 6
Maintenance
General ...................................................................... 7
Cleaning the cutter..................................................... 7
Lubricating the cutter ................................................. 7
Disassembly .............................................................. 8
Assembly ..............................................................9-11
Exploded View ............................................................. 12
Parts List ...................................................................... 13
Table of Contents
Description
Greenlee 763 and 764M4 Ratchet Cable Cutters are
non-insulated cutting tools intended for use on copper
and standard aluminum electrical cable. The 763 will
accommodate up to 500 MCM copper or 795 MCM
aluminum cable. The 764M4 will cut up to 750 MCM
copper or 795 MCM aluminum cable.
Both cable cutters ratchet and are equipped with fiber-
glass handles and rubber grips to limit operator fatigue.
They are not intended for use on ACSR (aluminum
cable, steel-reinforced) cable.
Purpose
This instruction manual is intended to familiarize person-
nel with the safe operation and maintenance procedures
for the following Greenlee 763 and 764M4 Cable Cutter.
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
Safety
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 specifications are nominal and may change as design improve-
ments occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
Loctite is a registered trademark of Loctite Corporation.
416 Super Bonder is a registered trademark of Loctite Corporation.
Molykote is a registered trademark of Dow Corning Corporation.
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Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
IMPORTANT SAFETY INFORMATION
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, defined below,
indicates the severity of the hazard. The message
after the signal word provides information for prevent-
ing 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
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.
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Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
IMPORTANT SAFETY INFORMATION
Electric shock hazard:
This is not an insulated tool.
Contact with live circuits could result
in severe injury or death.
• This tool is intended for two-handed operation.
Maintain a firm grip on both handles during
operation.
• Do not cut ACSR or steel.
• 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 flying debris.
Keep hands away from closing
blades.
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Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
Specifications
763 764M4
Mass/Weight ...................................................................................2.15 kg (4.75 lb) ............................ 2.4 kg (5.25 lb)
Length ............................................................................................ 349 mm (13.75") ........................ 486 mm (19.125")
Width at blades .............................................................................. 102 mm (4.03") ............................ 102 mm (4.03")
at handles ............................................................................ 132 mm (5.19") ................................. 152 mm (6")
Thickness ........................................................................................... 63.5 mm (2.5") ............................. 63.5 mm (2.5")
Jaw opening (minimum).................................................................... 30 mm (1.188") ............................ 30 mm (1.188")
Handle force at Maximum Copper Capacity......................................... 334 N (75 lb) ................................ 267 N (60 lb)
Maximum Rated Capacity
Copper (600-Volt Building Wire) .............................................. 240 mm2(500 Kcmil) ................... 400 mm2(750 Kcmil)
Aluminum (600-Volt Building Wire).......................................... 400 mm2(795 Kcmil) ................... 400 mm2(795 Kcmil)
Communications Cable.............................................................30 mm (1.188") O.D. ....................30 mm (1.188") O.D.
Frequent Use
Copper (600-Volt Building Wire) ...............................................170 mm2(350 MCM) ....................240 mm2(500 MCM)
Aluminum (600-Volt Building Wire)...........................................240 mm2(500 MCM) .................... 400 mm2(750 MCM)
Identification
Grips
Stationary
handle
Stationary
Jaw
Release
knob
Release
Movable
handle
Movable
Jaw
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Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
Operation
• This tool is intended for two-handed operation.
Maintain a firm 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.
1. Place the cable to be cut between the jaws.
2. Press the handles together until the ratchet clicks
once.
3. Open the handles until the ratchet clicks again.
4. Repeat steps 2 and 3 until cable is completely cut.
5. To open the blades, lift the movable handle until it
stops. Press the release knob outward as shown.
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 flying debris.
Release
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Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
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.
Cleaning the cutter
Blow dirt and/or cable particles out of the drive
mechanism with compressed air.
Lubricating the cutter
Close jaws and place 3-in-1 oil or equivalent on the
blades. Oil the jaw bolt (25), spacer (4), and jaw areas
around them. Also oil the master gear (16) and pawls (15)
at their respective shafts (19) and contact surfaces. Oil
the inside of the housing plates (13, 23) where contacted
by the lever handle plates (14, 22). Open and close the
cutter to spread the oil.
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 flying debris.
Pinch points:
Keep hands away from moving
parts.
Keep hands away from closing
blades.
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Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
Disassembly
This tool consists of three basic operating mechanisms
(see Figure 1).
1. Cutter jaw mechanism: stationary jaw (1), movable
jaw (3), jaw bolt (25), jaw spacer (4), return spring (5),
and related hardware.
2. Jaw drive mechanism: master drive gear (16),
master gear shaft (26), drive pawl (15), pawl spring
(12), pawl shaft (19), top and bottom handle plates
(14, 22) and operating lever.
3. Jaw holding mechanism: holding pawl (15), pawl
spring (17), pawl shaft (19) and pawl release pin
(27).
Maintenance (cont’d)
Both the jaw mechanism and drive mechanism can
be removed and serviced without disassembly of the
housing.
1. Remove cap screw (21). Release tension on exten-
sion spring (5) by opening the operating lever and
rotating release pin (27) outward.
2. Remove nut (6).
3. Remove bolt (25) and spacer (4).
4. Disconnect spring (5) from housing (13).
5. Remove retaining ring (9) from gear shaft (26).
Also remove two screws (8) from stop pin (20).
6. Remove shaft (26) and gear (16).
7. Remove the operating lever assembly.
8. Remove rubber bumpers (10) from release pin (27).
9. Remove two housing screws (11). Lift housing from
tool.
10. Remove two screws (11) to disassemble operating
lever assembly and remove pawl (15), pawl spring
(12) and pawl shaft (19).
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Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
Assembly
Maintenance (cont’d)
Figure 1
2,8
35,7 16 13 20 14
28
19
31
12
13
27
15
28 29
30
11
22
23
21
6,25
21
9,26 10
11*
JAW HOLDING
MECHANISM
LUBRICATION
POINTS -
USE MOLYKOTE®
SPRING
ANCHOR PIN
JAW DRIVE
MECHANISM
OPERATING
LEVER
1
*Note: Tighten to 19.2 - 21.4 Nm
(170-190 in-lb)
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Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
763 and 764M4 Ratchet Cable Cutter
Note: Use Loctite
®
262 Threadlocker on all screws
and tighten all 5/16" diameter screws to 190/170 in-lb.
Use Loctite 416 Super Bonder
®
(cyanoacrylate) to attach
release pin bumpers (10). Lubricate moving parts with
Molykote
®
grease (see Figure 1).
Assembly (cont’d)
1.
Assemble handle assembly (39) to bottom of housing
plate (13) using two screws (11).
2. Install stop pin (20). Place a spare 3/8" x 1.500"
screw through the master gear hole in bottom
housing plate (13) and place assembly on bench
with screws up (see Figure 2).
3. Lubricate pawl shaft (19) and assemble pawl shaft,
pawl (15) with pin (33) projecting from pawl surface,
spring (12), bottom handle plate (14) and top handle
plate (22) to handle assembly using two screws (11).
The long leg of the spring goes against the bottom
handle adapter (28) and the short leg goes under the
pawl (see Figure 3).
4. Insert master gear (16) between top and bottom
handle plates against drive pawl (15) and assemble
over spare screw in bottom housing plate (see
Figure 4).
5. Place holding pawl (15) with release pin (27) and
spring (17) over hole in bottom housing plate and
insert lubricated pawl shaft (19). The pawl will
engage the master gear. The long leg of the spring
goes against the handle adapter (28) where it
touches the bottom housing plate and the short leg
goes under the pawl (see Figure 4).
6. Thread housing cover (35) between handle plates
above the master gear—between spring (17) and
handle adapter (28) (see Figure 4).
Maintenance (cont’d)
14
22
28
19
15
12
Figure 3
13 20
Figure 2
26
9
26
16
15 27 19 17 28
13
28
23
Figure 4
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