Greenlee 980 Instruction Manual
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Greenlee 980 Instruction Manual

Hydraulic power pump
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INSTRUCTION MANUAL
®
980
Hydraulic Power Pump
Serial Code WW
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 8809.7
© 2002 Greenlee Textron
IM 1022 REV 14 12/02

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  • Page 1 INSTRUCTION MANUAL ® Hydraulic Power Pump Serial Code WW Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 999 8809.7 © 2002 Greenlee Textron IM 1022 REV 14 12/02...

  • Page 2: Table Of Contents

    690 bar (10,000 psi). This pump is intended to provide hydraulic power for an accessory with a single-acting ram such as a Greenlee conduit bender or cable cutter. This pump has a factory-set internal pressure relief valve.

  • Page 3: Safety

    Greenlee / A Textron Company 980 Hydraulic Power Pump Do not connect the pump to any system or system component other than those supplied by Greenlee. Other manufacturers’ components may not with- stand the maximum pressure and may fail. Nearby personnel can be injured by flying components and hydraulic oil.
  • Page 4 • Do not use fingers or hands to check for leaks. • Depressurize hydraulic system before servicing or disconnecting the hose. Greenlee / A Textron Company 980 Hydraulic Power Pump Wear eye protection when using this tool. Failure to wear eye protection can result in serious eye injury from flying debris or hydraulic oil.

  • Page 5: Specifications

    Length ... 305 mm (12") Width ... 305 mm (12") Height ... 445 mm (17.5") Weight/Mass ... 32 kg (71 lbs) Greenlee / A Textron Company 980 Hydraulic Power Pump ® 13M) 6 cSt at 100 C (46 SSU at 210 F) Volume 4455 Boeing Dr.

  • Page 6: Setup

    2. Remove any dust plugs from couplers. 3. Hand-tighten all couplings firmly (until all threads are fully engaged). Do not use tools. Greenlee / A Textron Company 980 Hydraulic Power Pump Electrical Connection Electric shock hazard: •...

  • Page 7: Operation

    3. Disconnect the hose slowly to release any trapped pressure. Greenlee / A Textron Company 980 Hydraulic Power Pump Note: To prevent leakage, this pump was shipped with an unvented plug installed in the reservoir fill hole. This plug must be replaced with the attached vented plug (6) before use.

  • Page 8: Maintenance

    3. Thoroughly clean the area around the fill hole. 4. Remove the vented reservoir plug. 5. Use Greenlee hydraulic fluid or an equivalent high- grade light hydraulic oil. See Specifications section of this manual to determine the correct type of hydraulic oil.

  • Page 9: Purging (Bleeding) Air

    7. Check the oil lever of the reservoir. Add oil if necessary. Greenlee / A Textron Company 980 Hydraulic Power Pump Draining and Flushing the System Note: Thoroughly clean the pump exterior before removing the reservoir.
  • Page 10 PROBLEM Motor will not start. Motor will not start under load. Greenlee / A Textron Company 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 and the Possible Remedy.

  • Page 11: Troubleshooting

    Motor starts, but stops when it encounters a load. Ram will not advance. Ram advances slowly. Ram will not advance completely. Greenlee / A Textron Company PROBABLE CAUSE Voltage supplied to motor is too low. Current rating of extension cord is too low.
  • Page 12 Ram will not advance completely. (cont’d) Ram advances erratically and retracts erratically. Greenlee / A Textron Company PROBABLE CAUSE The intake strainer is dirty or clogged. Motor rotates in the wrong direction. Low-pressure relief valve is dirty or is set incorrectly.
  • Page 13 Troubleshooting—Hydraulic Pump (cont’d) PROBLEM Pump will not build enough pressure to complete the job. Ram advances slowly. Greenlee / A Textron Company PROBABLE CAUSE High-pressure system is faulty. System has an external hydraulic leak. Pilot-operated valve will not close. Low-pressure system is at fault.
  • Page 14 Troubleshooting—Hydraulic Pump (cont’d) PROBLEM Ram will not hold pressure. Greenlee / A Textron Company PROBABLE CAUSE System has an external leak. Manual control valve needs adjustment or repair. The manual control valve is not in correct position. The manual control valve needs to be adjusted.
  • Page 15 Troubleshooting—Hydraulic Pump (cont’d) PROBLEM Ram will not retract. Greenlee / A Textron Company PROBABLE CAUSE The manual control valve is not in correct position. The manual control valve needs to be adjusted. Quick-couplers are not fully threaded together. Manual control valve set incorrectly.
  • Page 16 PROBLEM Pilot-operated valve will not open. Pilot-operated valve will not open fully. Pilot-operated valve opens too slowly. Greenlee / A Textron Company PROBABLE CAUSE The pilot piston does not return freely. Oil is cold. Wrong oil viscosity. Oil is dirty.
  • Page 17 Troubleshooting—Pilot-Operated Valve (cont’d) PROBLEM Pilot-operated valve will not close. Greenlee / A Textron Company 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. The ball seat of the low-pressure bypass check valve is damaged.
  • Page 18 Troubleshooting—Pilot-Operated Valve (cont’d) PROBLEM Pilot-operated valve will not close. (cont’d) Greenlee / A Textron Company PROBABLE CAUSE A particle of dirt or some other foreign object is holding the low-pressure relief valve open. Low-pressure relief valve is set too low.

  • Page 19: Service

    START RED (8) MOTOR (FRANKLIN) BLACK (2) BLUE (4) VIOLET (9) BROWN (10) ORANGE (5) Greenlee / A Textron Company BLACK WIRE GREENLEE MOTOR L1 ELECTRONIC MOTOR CONTROL MOTOR GROUND APPLY THERMALLOY THERMAL COTE 1 THERMAL GREASE TO BOTTOM OF RELAY...
  • Page 20 (3) Low-pressure relief valve — 19 bar (275 psi) located in pilot-operated valve (7) Piston (4) Low-pressure bypass check valve (5) High-pressure pump 980 — 1.04 liters/min. (63.5 in /min) at 3450 rpm (100%) (6) High-pressure relief valve — 717/690 bar (10,400/10,000 psi) (7) Pilot-operated directional control valve —...

  • Page 21: Repairs

    MOTOR SHAFT MOTOR FACE 4.6mm (.180 inch) 4.1mm (.160 inch) Greenlee / A Textron Company 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).
  • Page 22 (46). Then, back out the stem 3-1/2 turns. Tighten nut (43). The resulting pressure setting should be approximately 19 bar (280 psi). Greenlee / A Textron Company Low-Pressure Bypass Check Pressure Adjustment When properly set to the dimension shown in Figure A5,...
  • Page 23 .050 mm (.012 .002 inches). Low Pressure Pump Drive Pin Assemble with cone point end in half-round keyway. Greenlee / A Textron Company 980 Hydraulic Power Pump Ball Seat Refinishing Refer to Figures B2, B3, and B4 for the proper drill size to refinish the conical seat and finish ream size.

  • Page 24: Exploded View

    Exploded View Fig. A2 Figs A1 & A5 Greenlee / A Textron Company 980 Hydraulic Power Pump Fig A4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 Serial...

  • Page 25: Exploded Views

    34 N 25 foot-pounds • 68 N 50 foot-pounds • 503 4369.6 Hydraulic Repair Kit 503 5464.7 Release Knob Retrofit Kit Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 980 Hydraulic Power Pump...

  • Page 26: Parts List

    905 3682.7 503 3517.0 503 2627.9 905 3829.3 905 1185.9 905 1460.2 Greenlee / A Textron Company DESCRIPTION Carrying Handle ... 2 1/4"-20 x 1-1/4" Hex Head Screw ... 8 Decal ... 1 Motor, 115 VAC, 1-1/2 HP ... 1...
  • Page 27 905 1290.1 905 0168.3 503 2626.0 905 1269.3 503 4796.9 503 3541.3 905 3827.7 Greenlee / A Textron Company 980 Hydraulic Power Pump DESCRIPTION #10 Flat Washer ... 2 1/4" Flat Washer ... 4 Mounting Strap ... 1 Counterweight ... 1 Set Screw, 1/4"-20 x 1/4"...
  • Page 28 905 3695.9 503 3733.5 503 3492.1 905 3580.7 905 0430.5 Greenlee / A Textron Company 980 Hydraulic Power Pump DESCRIPTION O-Ring, 1/2" x 5/8" x 1/16" ... 1 Cap Screw, 5/16"-18 x 2.50 ... 2 Release Valve Body ... 1 O-Ring Plug (includes 107) ...
  • Page 29 * Parts included in Hydraulic Repair Kit No. 503 4369.6 +Parts included in Release Knob Retrofit Kit 503 5464.7 440 fd. 460-552 fd. Greenlee / A Textron Company DESCRIPTION Hex Nut, #6–32 ... 3 96" Long Cord ... 1 Pendant Switch Unit ... 1 (Consists of 85-90) Nylon Spacer, .150 ID x 5/16"...
  • Page 30 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 • Greenlee Textron is a subsidiary of Textron Inc. (800) 451-2632 (815) 397-1865 (800) 524-2853 Printed in USA...

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