Greenlee 756 Installation Manual

Page 1

INSTRUCTION MANUAL

756 and 757

Ratchet Cable Cutters

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

Page 2

756 and 757 Ratchet Cable Cutters

Table of Contents

Description .................................................................... 2

Safety ............................................................................ 2

Purpose of this Manual ................................................. 2

Important Safety Instructions ........................................ 3

Specications ................................................................ 4

Operation ....................................................................... 4

Maintenance ............................................................... 5-7

Illustration ...................................................................... 8

Parts List

756 ........................................................................ 9-10

757 ...................................................................... 11-12

Description

The Greenlee 756 and 757 Ratchet Cable Cutters are non-insulated tools.

• The 756 is intended to cut copper and aluminum cable up to 1500 kcmil.

• The 757 is intended to cut ACSR up to 954 kcmil and

1/2" soft steel rod.

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.

Purpose of this Manual

This instruction manual is intended to familiarize personnel with the safe operation and maintenance procedures

for the Greenlee 756 and 757 Ratchet Cable Cutters.

Keep this manual available to all personnel.

Replacement manuals are available upon request at no charge at www.greenlee.com.

All specications are nominal and may change as design

improvements occur. Greenlee Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products.

KEEP THIS MANUAL

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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IMPORTANT SAFETY INFORMATION

SAFETY ALERT SYMBOL

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, dened below,

indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

756 and 757 Ratchet Cable Cutters

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 or

servicing this tool.

Failure to wear eye protection could result in serious eye injury from ying debris.

Hazards which, if not avoided, COULD result in

severe injury or death.

Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.

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.

Keep hands away from the blades

• This tool is intended for two-handed operation. Maintain a rm grip on both handles when using this tool. Using this tool in any other manner can

result in injury or property damage.

• Inspect before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel.

• Do not perform any service or maintenance other

than as described in this manual. Injury or damage to the tool may result.

• Do not exceed the rated cutting capacity of this tool. The tool may break and cause injury or

property damage.

Failure to observe these precautions may result in injury or property damage.

and sprocket.

The spring-loaded mechanism could close unexpectedly, resulting in

personal injury. Disengage the spring before servicing this tool.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

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Speciﬁcations

756 Ratchet Cable Cutter

Cutterhead

Weight ........................................................................................................4.5 kg (10 lb)

Length.................................................................................................. 69.85 cm (27.5")

Jaw Opening .............................................................................................. 5.08 cm (2")

Maximum Capacity....................................... 1500 kcmil (630 mm2) Copper/Aluminum

757 Ratchet Cable Cutter

756 and 757 Ratchet Cable Cutters

Grip

Keeper Unit

Weight .....................................................................................................5.2 kg (11.5 lb)

Length.................................................................................................. 74.3 cm (29.25")

Jaw Opening ...........................................................................................30 mm (1.18")

Maximum Capacity............................................................................. 954 kcmil ACSR,

Operation

1. Grip both handles rmly.

2. Pull the handles apart to open the blades.

3. Place the wire between the blades.

4. Allow the chain spring to close the blades while keeping a rm grip on the handles.

• Standard cutting: To cut smaller wire, press the

handles together.

• Ratchet cutting: To cut larger wire, use the ratchet

by opening the shorter handle until it clicks once. Close the handle until it clicks once. Repeat this

ratcheting process until the cut is complete.

5. Open the handles completely to release.

1/2" (12.7 mm) soft steel rod

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 5

Maintenance

Keep hands away from the blades

General

• Keep grips clean and dry.

• Keep the blades sharp. If the cutting surfaces are

chipped or nicked, sharpen or replace the blades.

Lubricate the blades

1. Clamp the long handle into a vise.

2. Grip the short handle and open the cutter.

3. Apply a light lm of B-2 Moly grease or an equiva-

lent over the blades with a small brush.

4. Close and open the cutter several times to spread

the lubricant.

Clean and lubricate the internal parts

1. Disassemble the cutter (refer to the disassembly

instructions in this manual).

2. Clean the parts with solvent.

3. Apply Mobilgrease

lent to each moving part.

4. Reassemble the tool.

Clean the cutter mechanism

Use compressed air to blow dirt and foreign particles

out of the ratchet mechanism.

and sprocket.

The spring-loaded mechanism could close unexpectedly, resulting in

personal injury. Disengage the spring before servicing this tool.

Special 53030-3 or an equiva-

Wear eye protection when using or

servicing this tool.

Failure to wear eye protection could result in serious eye injury from ying debris.

756 and 757 Ratchet Cable Cutters

Disengage the Spring

1. Clamp the long handle (31) into a vise with the short handle (53) parallel to the oor and with the head

pointing away from you.

2. Remove the rubber grip (43).

3. Unhook the spring (39) from the pin (40) in the short handle (53) (see Figure 1).

Figure 1

Disassembly

1. Clamp the long handle (31) into a vise with the short handle (53) parallel to the oor and with the head

pointing away from you.

2. Remove the rubber grip (43).

3. Unhook the spring (39) from the pin (40) in the short handle (53) (see Figure 1).

4. Loosen nut (20) from bolt (19) using 7/16" wrenches.

5. Remove bolt and snubber (16).

6. Remove tool from vise.

7. Unhook two closing springs (15).

8. Remove bolt (19) and nut (20) and snubber (16).

9. Remove cutterhead from handles using 9/16" wrenches.

10. Remove right handle assembly, with the chain and spring still attached, from the left handle.

11. Remove retaining ring (54) from sprocket pin (51).

12. Remove sprocket pin (51).

13. Remove 2 side plates (55), sprocket (56), washer (57), pin (23), detent pawl (28), and spring (36).

14. Clean all parts thoroughly with solvent.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 6

Maintenance (cont’d)

Assembly

1. Assemble sprocket pin (51) to one side plate (55). Lay this assembly on the bench with the notched edge of the plate nearest you (see Figure 3).

Figure 3

Figure 2

2. Apply a light lm of grease to the shank of the pin.

3. Slide sprocket (56) onto pin.

4. Apply grease to the detent pin (23) and slide into the detent pawl. Place the detent spring (36) onto the pin making sure the spring ends have not been

bent out of shape. The cross arm of the spring goes under the at side of the arrow shaped point of the

detent pawl (see Figure 2).

5. Assemble one end of detent pin (23) into the hole on side plate (55) and engage the rounded end of the sprocket (56) (see Figure 3).

Figure 4

Figure 5

756 and 757 Ratchet Cable Cutters

Figure 6

10. Secure sprocket pin with retaining rings (54). (This assembly must be free to pivot freely.)

11. With a small hook tool, reach up from the bottom of the assembly, between the plates and hook the

ends of the detent spring into their respective holes

(see Figure 7). Check to be sure spring loops are not

caught between the pin and the side plate.

12. Remove the 1/8" pin from under the pawl and engage the drive pawl with sprocket (56).

13. Remove the handle from the vise.

14. Hook the longer loop on the chain spring (39) onto the free end of the chain (38). Lay the left and right

handles on the bench. The drive pawl is located in the left handle. The chain is attached to the right handle. Feed the spring on the chain over the

sprocket and into the left handle (see Figure 9).

Figure 7

6. Match up the second plate (55) with the rst, and

place over the detent pin and pivot bolt. Do not

insert spring ends into plates at this point (see Figure 4).

7. Hold the left handle (53) in vise with the drive pawl facing up and the handle pointing to your left (see Figure 5). Pull the drive pawl up, moving counterclockwise, and insert a 1/8" pin (rod or nail) through

the small holes in the plates near the drive pawl to

hold it in a horizontal position (see Figure 5).

8. Grasp the side plate assembly rmly with the notched edges of the plate facing down. While holding tightly between ngers, remove the sprocket

pin (see Figure 6).

9. Carefully insert the plate assembly into the left handle between the washers (57). Align the holes and slide the sprocket pin into position.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Figure 8

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Maintenance (cont’d)

15. With handles remaining in this position, assemble

the cutting head to the left handle. The thick spacer (25) goes between the blade holders (see Figure 9). Use the longer bolt (12) and nut (26) and tighten

securely.

Figure 9

16. Assemble the other side of the head to the right

handle using bolts (12), nuts (26) and washer (7).

Tighten securely.

17. Hook open end of closing spring (15) into holes in

handle (53) so that closed loops will be against side plates (55).

18. Insert bolt (19) through closed loop on one of the

springs (15) and insert through 1/4 inch hole in side plate (55). At the same time assemble snubber (16)

and slide bolt through snubber.

19. Assemble other spring (15) onto bolt and assemble

nut onto bolt.

20. Tighten nut approximately one thread beyond end

of bolt.

21. Hook the chain spring (39) over pin at end of the left

handle (see Figure 10).

22. Assemble snubber (16) and bolt (19) to handle.

Assemble nut and tighten so as not to bind assembly (see Figure 11).

756 and 757 Ratchet Cable Cutters

Figure 10

Figure 11

23. Check operation of the tool by opening and closing. If operation is satisfactory, proceed to next step.

24. Assemble grip to left handle (53). There is a “key” in the interior of the grip. Align this key with the slot in the left (or ratcheting) handle, and push the

grip over the handle. No lubrication or adhesive is

needed. Assemble clamp to grip and tighten.

If sliding a replacement grip over a replacement

right handle (31), spread a small amount of soapy

water over the handle to ease assembly. It will eventually dry out and allow a solid adhesion to the

handle. The grip requires pounding to t over the

handle.

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 8

Illustration

756 and 757 Ratchet Cable Cutters

Repair Kit

757 Cutter Head

38 39

756 Cutter Head

31B

31A

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 9

756 and 757 Ratchet Cable Cutters

Parts List

756 (for serial codes after ZDHA)

Key Part No. Description Qty

2 Blade (included in 50341880 kit) .............................................................. 2

4 Bolt, 1/2-20 x 1-1/4 pivot .......................................................................... 1

5 Nut, 1/2-20 hex slotted ............................................................................. 1

6 Pin, ø3/32 x 3/4 drive ................................................................................ 1

12 Screw, 3/8-24 x 1-1/2 hex head cap ........................................................ 4

15 Spring, extension ...................................................................................... 2

16 Snubber, chain .......................................................................................... 2

19 Screw, 1/4-20 x 1-3/4 socket head cap (order with item 20) .................... 2

20 Nut, 1/4-20 hex lock (order with item 19) ................................................. 2

23 50341677 Pin, detent ................................................................................................. 1

24 Spacer, thin ............................................................................................... 2

25 50341693 Spacer ....................................................................................................... 2

26 Nut, 3/8-24 hex lock ................................................................................. 4

28 50341650 Pawl, detent .............................................................................................. 1

29 90527879 Link, chain connector (included with item 38)

30 50341596 Bushing ..................................................................................................... 1

31 50362119 Right handle unit (includes items 31A, 31B, 43) ....................................... 1

31A 50021621 Decal, identication, Model 756 ............................................................... 1

31B 50021630 Decal, warning .......................................................................................... 1

33 50341758 Spring, drive pawl ..................................................................................... 1

34 50341642 Pawl, drive ................................................................................................. 1

36 50341766 Spring, torsion ........................................................................................... 1

37 Ring, retainer ............................................................................................. 4

38 50341723 Chain (includes item 24) ............................................................................ 1

39 50341774 Spring, chain ............................................................................................. 1

40 Rollpin, ø1/8 x 1-1/8 ................................................................................. 1

43 50340832 Grip, handle............................................................................................... 2

51 Pin, sprocket ............................................................................................. 1

52 Pin, pawl drive ........................................................................................... 1

53 Handle, left ................................................................................................ 1

54 Ring, retaining ........................................................................................... 2

55 Side plate .................................................................................................. 2

56 Sprocket .................................................................................................... 1

57 Washer, 5/8 at ......................................................................................... 2

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 10

756 and 757 Ratchet Cable Cutters

Repair Parts List

756 (for serial codes after ZDHA)

Key Part No. Description

1 50341880 756 cutterhead (includes items 2, 4, 5, 6, 12, 24, 26)

Recommend replacing pivot bolt and nut whenever blades are replaced

13 50341898 756 and 757 repair kit (includes items 15, 16, 19, 20)

47* Nut, 7/16-20 hex slotted

48* Bolt, 7/16-20 x 1-1/8 hex head

50 50356410 756 pivot bolt assembly (includes items 4, 5, 6, 47, 48)

*Use 7/16" bolt and nut only with 5/16" thick blades (earlier model)

Ratchet Mechanism Upgrade Kit

756 (upgrades ratchet mechanism on cutters with no serial code)

Key Part No. Description

58 50372327 Ratchet mechanism (includes items 37, 51, 52, 53, 54, 55, 56, 57)

Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Page 11

756 and 757 Ratchet Cable Cutters

Parts List

757 (for serial codes after ZDHA)

Key Part No. Description Qty

4 Bolt, 1/2-20 x 1-1/4 pivot .......................................................................... 1

5 Nut, 1/2-20 hex slotted ............................................................................. 1

6 Pin, ø3/32 x 3/4 drive ................................................................................ 1

8 Blade unit (included in 50341871 kit) ........................................................ 2

10 Keeper unit ................................................................................................ 1

11 Screw, 5/16-18 x 1/2 hex cap ................................................................... 2