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Greenlee 976-22 Service Manual

Hydraulic power pumps
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SERVICE MANUAL
976-22 and 980-22
Hydraulic Power Pumps
Serial Codes YD and ABZ
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99945940 REV 3
© 2005 Greenlee Textron Inc.
12/05

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Summary of Contents for Greenlee 976-22

  • Page 1 SERVICE MANUAL 976-22 and 980-22 Hydraulic Power Pumps Serial Codes YD and ABZ Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 99945940 REV 3 © 2005 Greenlee Textron Inc. 12/05...

  • Page 2: Table Of Contents

    For recycling information, go to www.greenlee.com. 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. 732 is a trademark of Dow Corning.

  • Page 3: Important Safety Information

    Failure to observe this warning will result in severe injury or death. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Do not connect the pump to any system or system component other than those supplied by Greenlee.
  • Page 4 Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Fill unit with hydraulic oil before operating pump. Failure to fill unit with oil will result in damage to the pump.

  • Page 5: Maintenance

    Adding Oil Do not use brake fluid. Brake fluid will ruin the seals. Refer to the “Parts List” in this manual for Greenlee hydraulic oil specification and Greenlee part number. 1. Place the control lever in the AUTO RELEASE position.
  • Page 6 7. Check the oil level of the reservoir. Add oil if necessary. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Draining and Flushing the System Note: Thoroughly clean the pump exterior before removing the reservoir.

  • Page 7: Hydraulic Pump

    Motor starts, but stops when it encounters a load. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps How to use this table: If your hydraulic pump does not operate properly, find the description of the problem under the “Problem” column. Read the “Probable Cause”...

  • Page 8: Troubleshooting

    Problem Ram will not advance. Ram advances slowly. Ram will not advance completely. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Probable Cause Low-pressure system has a partial or complete failure. Unvented plug has not been replaced.

  • Page 9: Troubleshooting

    Pump will not build enough pressure to complete the job. Ram advances slowly. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Probable Cause Air in the hydraulic fluid. High-pressure system is faulty. System has an external hydraulic leak.
  • Page 10 Troubleshooting—Hydraulic Pump (cont’d) Problem Ram will not hold pressure. Ram will not retract. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Probable Cause System has an external leak. Manual control valve needs adjustment or repair. The manual control valve is not in correct position.
  • Page 11 Pilot-operated valve will not open. Pilot-operated valve will not open fully. Pilot-operated valve opens too slowly. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Probable Cause The pilot piston does not return freely. Oil is cold. Wrong oil viscosity.

  • Page 12: Pilot-Operated Valve

    Troubleshooting—Pilot-Operated Valve (cont’d) Problem Pilot-operated valve will not close. Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Probable Cause A particle of dirt or some other foreign object is holding the low-pressure bypass check valve open. Low-pressure bypass check valve is faulty.

  • Page 13: Service

    Motor Control with Cover Removed, Side View Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps POWER CORD GREENLEE ELECTRONIC MOTOR CONTROL GREEN WHITE...
  • Page 14 3-way, 2-position 8 Manually operated check valve 9 Female coupler half Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps 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 ®...
  • Page 15 4.6 mm (0.180") 4.1 mm (0.160") Figure A1 8 Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Manual Release/Automatic Release Valve Handle Setting Refer to Figures A2 and A3. 1. Thread in the shaft (62) until it just touches the check ball (55) (in its spring-loaded closed position).
  • Page 16 37.29 mm (1.468") Figure A5 4 Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Check Ball Travel at High-Pressure Inlet The amount of allowable ball travel is critical to the optimum high-pressure output (flow rate). Refer to Figure A5-1.
  • Page 17 (LO-P RELIEF VALVE) 4.76 mm (0.187") Ø REAM Figure B2 3 Figure B3 4 Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps COVERPLATE 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...

  • Page 18: Illustrations

    976-22 and 980-22 Hydraulic Power Pumps Illustration Serial Fig. A2 Figs. A1 and A5 Fig. A4 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 19 68 Nm 50 ft-lb 503 4369.6 Hydraulic Repair Kit 503 5464.7 Release Knob Retrofit Kit Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 976-22 980-22 41 980-22...

  • Page 20: Parts List

    1/4–20 x 1-1/4" Hex head screw ... 8 Decal, identification (976-22) ... 1 Decal, identification and specification (980-22) ... 1 Motor, 220 VAC, 1/2 hp (976-22) ... 1 Motor, 220 VAC, 1-1/2 hp (980-22) ... 1 GE Motor 5KC49TG20T Stk #739...
  • Page 21 50323709 91862655 50319027 90534417 50319019 50323628 Greenlee / A Textron Company 976-22 and 980-22 Hydraulic Power Pumps Description Ball bearing, #3206 ... 1 Ball, 3/16" ... 2 Jam nut, 1/2–20 ... 1 Stem ... 1 Spring ... 1 Ball, 1/4" ... 1 Spring ...
  • Page 22 4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070 An ISO 9001 Company www.greenlee.com 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 800-435-0786 Fax: 800-451-2632 815-397-7070 Fax: 815-397-1865 800-435-0786 Fax: 800-524-2853 Fax: +1-815-397-9247 Greenlee Textron Inc. is a subsidiary of Textron Inc. • Printed in USA...

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980-22

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