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Instruction Manual
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Greenlee 763, 764M4 Instruction Manual

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Page 1
INSTRUCTION MANUAL
763 & 764M4
Ratchet Cable Cutters
99928752 © 2006 Greenlee Textron Inc. IM 1360 REV 2 5/06
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
Page 2
763 and 764M4 Ratchet Cable Cutter
Table of Contents
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
Description
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
This instruction manual is intended to familiarize person­nel 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.
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 fiber­glass handles and rubber grips to limit operator fatigue.
They are not intended for use on ACSR (aluminum cable, steel-reinforced) cable.
All specifications 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.
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.
KEEP THIS MANUAL
Page 3
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, defined 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.
763 and 764M4 Ratchet Cable Cutter
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.
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.
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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.
Keep hands away from closing blades.
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.
• 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.
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Identification
Movable
Stationary
Jaw
Jaw
763 and 764M4 Ratchet Cable Cutter
Movable
handle
Grips
Stationary
Release
knob
handle
Release
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)
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Operation
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.
763 and 764M4 Ratchet Cable Cutter
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.
Release
• 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.
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Maintenance
763 and 764M4 Ratchet Cable Cutter
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
Wear eye protection when using this tool. Failure to wear eye protection could result in serious eye injury from flying debris.
Blow dirt and/or cable particles out of the drive mechanism with compressed air.
Lubricating the cutter
Keep hands away from closing blades.
Pinch points: Keep hands away from moving
parts.
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.
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Maintenance (cont’d)
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).
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 exten­sion 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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Maintenance (cont’d)
Assembly
LUBRICATION
POINTS -
USE MOLYKOTE
®
22
1
763 and 764M4 Ratchet Cable Cutter
Figure 1
SPRING
ANCHOR PIN
JAW DRIVE
MECHANISM
20
14
28
19
12
OPERATING
LEVER
31
2,8
5,7
3
16
13
9,26
6,25
21
21
10
23
11*
11
JAW HOLDING
MECHANISM
*Note: Tighten to 19.2 - 21.4 Nm
(170-190 in-lb)
15
13
27
28
29
30
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Maintenance (cont’d)
Assembly (cont’d)
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 release pin bumpers (10). Lubricate moving parts with Molykote
1.
®
grease (see Figure 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).
®
Figure 2
(cyanoacrylate) to attach
763 and 764M4 Ratchet Cable Cutter
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).
13
20
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).
Figure 3
22
28
Figure 4
23
28
26
9
26
13
16
15
27 19 17 28
14
12
19
15
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Maintenance (cont’d)
Assembly (cont’d)
7. Place top housing plate (23) over tool assembly,
using spare 3/8" screw and release pin (27) for alignment. Assemble nuts (18) loosely to hold housing in place.
8. Lubricate gear shaft (26) and assemble in place of
3/8" spare screw.
9. Assemble retaining ring (9) to gear shaft (26).
10. Assemble bumpers (10) to pin (27).
763 and 764M4 Ratchet Cable Cutter
Note: To replace jaws, see steps 11-18; also see Figure 5 and exploded view. To replace entire cutter head (38), skip steps 11, 12, and 15.
11.
Assemble spring (5) to movable jaw (3) using stud (7).
12. Assemble screw (2) and nut (8) into movable jaw (3).
13. Reconnect spring (5) to housing (13).
14. Assemble fixed jaw (1), movable jaw (3) and spacer (4) into housing assembly using lubricated bolt (25), nut (6) and two nut retainers (24).
15. Assemble jaw anchor screw (21).
16. Tighten nut (6) to a maximum jaw clearance of .2 mm (0.007"). To achieve .2 mm (0.007") clearance, tighten nut (6) snugly so that jaws are against each other. Then back off nut to the first open slot aligned with the drive pin hole. There should be not more than .2 mm (0.007") gap between blades. Operate the cutter to ensure that the jaws move freely.
17. Bend tab (5) on nut retainer (24) to secure nut (6).
18. Apply adhesive Loctite 416 Super Bonder sparingly to assemble two bumpers (10) (see Figure 1).
Figure 5
25
24
3
7
5
6
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Illustration
763 and 764M4 Ratchet Cable Cutter
32
18
10
9
6
31
29
6
Key 38
Cutterhead
8
24
13
14
7
4
8
3
7
24
5
4
2
5
1
18
28
15
33
16
19
20
22
12
11
23
35
27
15
11
30
29
28
17
19
11
34
10
32
3
2
1
25
24
25
21
26
21
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763 and 764M4 Ratchet Cable Cutter
Parts List
763 764 M4
Key Part No. Part No. Description Qty
1 50386255 50386255 Jaw, stationary cutter.........................................................................1
2 90505794 90505794 Screw, 1/4–20 x .500" socket head ................................................... 1
3 50384759 50384759 Jaw, movable cutter...........................................................................1
4 50355325 50355325 Spacer, 0.380" x .750" x .376"...........................................................1
5 90539850 90539850 Spring, extension 0.202" x .300" x 2.75" ...........................................1
6 90541197 90541197 Nut, hex, 3/8–24 ................................................................................1
7 90535995 90535995 Stud, 0.161" x .500" ........................................................................... 1
8 90541200 90541200 Nut, 1/4–20 lock.................................................................................1
9 90504534 90504534 Ring, retaining, Truarc® #5100-37 .....................................................1
10 90539427 90539427 Bumper, 0.187" x .375" x .500" rubber .............................................. 2
11* 90552652 90552652 Screw, cap, 5/16–24 x 1.25"..............................................................4
12 50381407 50381407 Spring, torsion ................................................................................... 1
13 50055690 50055690 Plate, housing bottom........................................................................1
14 50355260 50355260 Plate, bottom handle..........................................................................1
15 50356488 50356488 Pawl ...................................................................................................2
16 50356461 50356461 Gear, master 12T .............................................................................. 1
17 50356216 50356216 Spring, torsion, 0.380" x .450" x .140"...............................................1
18* F009550 F009550 Nut, 5/16–24 lock...............................................................................5
19 50355384 50355384 Shaft, pawl 0.312" x 1.00" .................................................................2
20 50384783 50384783 Pin, stop ............................................................................................. 1
21 90539877 90539877 Screw, cap, 5/16–18 x .312" socket head .........................................1
22 50355252 50355252 Plate, top handle................................................................................1
23 50399110 50055674 Plate, housing top .............................................................................. 1
24 50384813 50384813 Retainer, nut ......................................................................................2
25 90542690 90542690 Bolt, blade, 3/8–24 x 1.75" ................................................................1
26 50055402 50055402 Shaft, master gear .............................................................................1
27 90539419 90539419 Pin, roll, 0.187" x 2.00" ......................................................................1
28* 50384937 50384937 Adapter, handle .................................................................................2
29* 50055550 50355406 Handle ...............................................................................................2
30* 50034669 50034669 Decal, warning...................................................................................1
31* 50351907 50351907 Decal, small Greenlee safety ............................................................1
32* 50223003 50223003 Grip, rubber, 0.995" x 1.50" x 5.09"...................................................2
33 90540077 90540077 Pin, roll, 0.187" x .375" ......................................................................1
34 90505247 90505247 Screw, cap, 5/16–18 x 1.500"............................................................1
35 50057219 50057219 Spacer ............................................................................................... 1
Repair Parts List
Key Part No. Description Qty
38 50360370 Cutter head
* 50358855 Handle assembly - one handle and hardware for 764M4
* 50059521 Handle assembly - one handle and hardware for 763
(includes keys 1–8, 21, 24, 25, 33) ............................................... 1
(includes keys 11, 18, 28-32) ........................................................ 1
(includes keys 11, 18, 28-32) ........................................................ 1
Page 14
USA 800-435-0786 Fax: 800-451-2632 815-397-7070 Fax: 815-397-1865 Canada 800-435-0786 Fax: 800-524-2853 International +1-815-397-7070 Fax: +1-815-397-9247
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company
www.greenlee.com
•
Greenlee Textron Inc. is a subsidiary of Textron Inc.
Printed in USA
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